Factory Workshop Manual
Make
Ford
Model
Explorer 4wd
Engine and year
V6-245 4.0L SOHC VIN K SFI (2001)
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This manual was submitted by
Anonymous
Date
1st January 2018
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104,
( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102
P0100 - P0104: Testing and Inspection P0102
For diagnosis of code P0102 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104,
( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 9
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104,
( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 10
P0100 - P0104: Testing and Inspection P0103
For diagnosis of code P0103 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0100 - P0104,
( P0101 P0102 P0103 0100 0101 0102 0103 0104 ) > System Information > System Diagnosis > P0102 > Page 11
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106
P0105 - P0109: Testing and Inspection P0106
For diagnosis of code P0106 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 16
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 17
P0105 - P0109: Testing and Inspection P0107
For diagnosis of code P0107 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 18
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 19
P0105 - P0109: Testing and Inspection P0108
For diagnosis of code P0108 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 20
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 21
P0105 - P0109: Testing and Inspection P0109
For diagnosis of code P0109 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0105 - P0109,
( P0106 P0107 P0108 0105 0106 0107 0108 0109 ) > System Information > System Diagnosis > P0106 > Page 22
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114,
( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112
P0110 - P0114: Testing and Inspection P0112
For diagnosis of code P0112 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114,
( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 27
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114,
( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 28
P0110 - P0114: Testing and Inspection P0113
For diagnosis of code P0113 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0110 - P0114,
( P0111 P0112 P0113 0110 0111 0112 0113 0114 ) > System Information > System Diagnosis > P0112 > Page 29
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116
P0115 - P0119: Testing and Inspection P0116
For diagnosis of code P0116 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 34
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 35
P0115 - P0119: Testing and Inspection P0117
For diagnosis of code P0117 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 36
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 37
P0115 - P0119: Testing and Inspection P0118
For diagnosis of code P0118 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0115 - P0119,
( P0116 P0117 P0118 0115 0116 0117 0118 0119 ) > System Information > System Diagnosis > P0116 > Page 38
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121
P0120 - P0124: Testing and Inspection P0121
For diagnosis of code P0121 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 43
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 44
P0120 - P0124: Testing and Inspection P0122
For diagnosis of code P0122 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 45
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 46
P0120 - P0124: Testing and Inspection P0123
For diagnosis of code P0123 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0120 - P0124,
( P0121 P0122 P0123 0120 0121 0122 0123 0124 ) > System Information > System Diagnosis > P0121 > Page 47
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129,
( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125
P0125 - P0129: Testing and Inspection P0125
For diagnosis of code P0125 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129,
( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 52
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129,
( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 53
P0125 - P0129: Testing and Inspection P0127
For diagnosis of code P0127 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0125 - P0129,
( P0126 P0127 P0128 0125 0126 0127 0128 0129 ) > System Information > System Diagnosis > P0125 > Page 54
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134,
( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131
P0130 - P0134: Testing and Inspection P0131
For diagnosis of code P0131 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134,
( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 59
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134,
( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 60
P0130 - P0134: Testing and Inspection P0133
For diagnosis of code P0133 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0130 - P0134,
( P0131 P0132 P0133 0130 0131 0132 0133 0134 ) > System Information > System Diagnosis > P0131 > Page 61
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139,
( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135
P0135 - P0139: Testing and Inspection P0135
For diagnosis of code P0135 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139,
( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 66
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139,
( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 67
P0135 - P0139: Testing and Inspection P0136
For diagnosis of code P0136 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0135 - P0139,
( P0136 P0137 P0138 0135 0136 0137 0138 0139 ) > System Information > System Diagnosis > P0135 > Page 68
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144,
( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis
P0140 - P0144: Testing and Inspection
For diagnosis of code P0141 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0140 - P0144,
( P0141 P0142 P0143 0140 0141 0142 0143 0144 ) > System Information > System Diagnosis > Page 72
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149,
( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis
P0145 - P0149: Testing and Inspection
For diagnosis of code P0148 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0145 - P0149,
( P0146 P0127 P0148 0145 0146 0147 0148 0149 ) > System Information > System Diagnosis > Page 76
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154,
( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151
P0150 - P0154: Testing and Inspection P0151
For diagnosis of code P0151 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154,
( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 81
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154,
( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 82
P0150 - P0154: Testing and Inspection P0153
For diagnosis of code P0153 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0150 - P0154,
( P0151 P0152 P0153 0150 0151 0152 0153 0154 ) > System Information > System Diagnosis > P0151 > Page 83
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159,
( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155
P0155 - P0159: Testing and Inspection P0155
For diagnosis of code P0155 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159,
( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 88
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159,
( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 89
P0155 - P0159: Testing and Inspection P0156
For diagnosis of code P0156 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0155 - P0159,
( P0156 P0157 P0158 0155 0156 0157 0158 0159 ) > System Information > System Diagnosis > P0155 > Page 90
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164,
( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis
P0160 - P0164: Testing and Inspection
For diagnosis of code P0161 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0160 - P0164,
( P0161 P0162 P0163 0160 0161 0162 0163 0164 ) > System Information > System Diagnosis > Page 94
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171
P0170 - P0174: Testing and Inspection P0171
For diagnosis of code P0171 refer to chart
Bxxxx, Cxxxx, P0102 - P0171
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 99
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 100
P0170 - P0174: Testing and Inspection P0172
For diagnosis of code P0172 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 101
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 102
P0170 - P0174: Testing and Inspection P0174
For diagnosis of code P0174 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0170 - P0174,
( P0171 P0172 P0173 0170 0171 0172 0173 0174 ) > System Information > System Diagnosis > P0171 > Page 103
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179,
( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175
P0175 - P0179: Testing and Inspection P0175
For diagnosis of code P0175 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179,
( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 108
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179,
( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 109
P0175 - P0179: Testing and Inspection P0176
For diagnosis of code P0176 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0175 - P0179,
( P0176 P0177 P0178 0175 0176 0177 0178 0179 ) > System Information > System Diagnosis > P0175 > Page 110
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180
P0180 - P0184: Testing and Inspection P0180
For diagnosis of code P0180 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 115
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 116
P0180 - P0184: Testing and Inspection P0181
For diagnosis of code P0181 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 117
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 118
P0180 - P0184: Testing and Inspection P0182
For diagnosis of code P0182 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 119
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 120
P0180 - P0184: Testing and Inspection P0183
For diagnosis of code P0183 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0180 - P0184,
( P0181 P0182 P0183 0180 0181 0182 0183 0184 ) > System Information > System Diagnosis > P0180 > Page 121
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190
P0190 - P0194: Testing and Inspection P0190
For diagnosis of code P0190 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 126
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 127
P0190 - P0194: Testing and Inspection P0191
For diagnosis of code P0191 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 128
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 129
P0190 - P0194: Testing and Inspection P0192
For diagnosis of code P0192 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 130
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 131
P0190 - P0194: Testing and Inspection P0193
For diagnosis of code P0193 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0100-P01ZZ > P0190 - P0194,
( P0191 P0192 P0193 0190 0191 0192 0193 0194 ) > System Information > System Diagnosis > P0190 > Page 132
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201
P0200 - P0204: Testing and Inspection P0201
For diagnosis of code P0201 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 138
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 139
P0200 - P0204: Testing and Inspection P0202
For diagnosis of code P0202 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 140
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 141
P0200 - P0204: Testing and Inspection P0203
For diagnosis of code P0203 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 142
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 143
P0200 - P0204: Testing and Inspection P0204
For diagnosis of code P0204 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0200 - P0204,
( P0201 P0202 P0203 0200 0201 0202 0203 0204 ) > System Information > System Diagnosis > P0201 > Page 144
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205
P0205 - P0209: Testing and Inspection P0205
For diagnosis of code P0205 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 149
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 150
P0205 - P0209: Testing and Inspection P0206
For diagnosis of code P0206 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 151
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 152
P0205 - P0209: Testing and Inspection P0207
For diagnosis of code P0207 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 153
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 154
P0205 - P0209: Testing and Inspection P0208
For diagnosis of code P0208 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 155
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 156
P0205 - P0209: Testing and Inspection P0209
For diagnosis of code P0209 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0205 - P0209,
( P0206 P0207 P0208 0205 0206 0207 0208 0209 ) > System Information > System Diagnosis > P0205 > Page 157
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210
P0210 - P0214: Testing and Inspection P0210
For diagnosis of code P0210 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 162
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 163
P0210 - P0214: Testing and Inspection P0211
For diagnosis of code P0211 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 164
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 165
P0210 - P0214: Testing and Inspection P0212
For diagnosis of code P0212 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0210 - P0214,
( P0211 P0212 P0213 0210 0211 0212 0213 0214 ) > System Information > System Diagnosis > P0210 > Page 166
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219,
( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis
P0215 - P0219: Testing and Inspection
For diagnosis of code P0217 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0215 - P0219,
( P0216 P0217 P0218 0215 0216 0217 0218 0219 ) > System Information > System Diagnosis > Page 170
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230
P0230 - P0234: Testing and Inspection P0230
For diagnosis of code P0230 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 175
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 176
P0230 - P0234: Testing and Inspection P0231
For diagnosis of code P0231 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 177
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 178
P0230 - P0234: Testing and Inspection P0232
For diagnosis of code P0232 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 179
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 180
P0230 - P0234: Testing and Inspection P0234
For diagnosis of code P0234 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0230 - P0234,
( P0231 P0232 P0233 0230 0231 0232 0233 0234 ) > System Information > System Diagnosis > P0230 > Page 181
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244,
( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis
P0240 - P0244: Testing and Inspection
For diagnosis of code P0243 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0240 - P0244,
( P0241 P0242 P0243 0240 0241 0242 0243 0244 ) > System Information > System Diagnosis > Page 185
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299,
( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis
P0295 - P0299: Testing and Inspection
For diagnosis of code P0298 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0200-P02ZZ > P0295 - P0299,
( P0296 P0297 P0298 0295 0296 0297 0298 0299 ) > System Information > System Diagnosis > Page 189
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300
P0300 - P0304: Testing and Inspection P0300
For diagnosis of code P0300 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 195
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 196
P0300 - P0304: Testing and Inspection P0301
For diagnosis of code P0301 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 197
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 198
P0300 - P0304: Testing and Inspection P0302
For diagnosis of code P0302 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 199
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 200
P0300 - P0304: Testing and Inspection P0303
For diagnosis of code P0303 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 201
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 202
P0300 - P0304: Testing and Inspection P0304
For diagnosis of code P0304 refer to chart
P0172 - P0304
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0300 - P0304,
( P0301 P0302 P0303 0300 0301 0302 0303 0304 ) > System Information > System Diagnosis > P0300 > Page 203
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305
P0305 - P0309: Testing and Inspection P0305
For diagnosis of code P0305 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 208
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 209
P0305 - P0309: Testing and Inspection P0306
For diagnosis of code P0306 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 210
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 211
P0305 - P0309: Testing and Inspection P0307
For diagnosis of code P0307 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 212
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 213
P0305 - P0309: Testing and Inspection P0308
For diagnosis of code P0308 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 214
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 215
P0305 - P0309: Testing and Inspection P0309
For diagnosis of code P0309 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0305 - P0309,
( P0306 P0307 P0308 0305 0306 0307 0308 0309 ) > System Information > System Diagnosis > P0305 > Page 216
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314,
( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis
P0310 - P0314: Testing and Inspection
For diagnosis of code P0310 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0310 - P0314,
( P0311 P0312 P0313 0310 0311 0312 0313 0314 ) > System Information > System Diagnosis > Page 220
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324,
( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis
P0320 - P0324: Testing and Inspection
For diagnosis of code P0320 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0320 - P0324,
( P0321 P0322 P0323 0320 0321 0322 0323 0324 ) > System Information > System Diagnosis > Page 224
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329,
( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325
P0325 - P0329: Testing and Inspection P0325
For diagnosis of code P0325 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329,
( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 229
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329,
( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 230
P0325 - P0329: Testing and Inspection P0326
For diagnosis of code P0326 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0325 - P0329,
( P0326 P0327 P0328 0325 0326 0327 0328 0329 ) > System Information > System Diagnosis > P0325 > Page 231
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334,
( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330
P0330 - P0334: Testing and Inspection P0330
For diagnosis of code P0330 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334,
( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 236
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334,
( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 237
P0330 - P0334: Testing and Inspection P0331
For diagnosis of code P0331 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0330 - P0334,
( P0331 P0332 P0333 0330 0331 0332 0333 0334 ) > System Information > System Diagnosis > P0330 > Page 238
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344,
( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis
P0340 - P0344: Testing and Inspection
For diagnosis of code P0340 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0340 - P0344,
( P0341 P0342 P0343 0340 0341 0342 0343 0344 ) > System Information > System Diagnosis > Page 242
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350
P0350 - P0354: Testing and Inspection P0350
For diagnosis of code P0350 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 247
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 248
P0350 - P0354: Testing and Inspection P0351
For diagnosis of code P0351 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 249
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 250
P0350 - P0354: Testing and Inspection P0352
For diagnosis of code P0352 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 251
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 252
P0350 - P0354: Testing and Inspection P0353
For diagnosis of code P0353 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 253
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 254
P0350 - P0354: Testing and Inspection P0354
For diagnosis of code P0354 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0350 - P0354,
( P0351 P0352 P0353 0350 0351 0352 0353 0354 ) > System Information > System Diagnosis > P0350 > Page 255
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355
P0355 - P0359: Testing and Inspection P0355
For diagnosis of code P0355 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 260
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 261
P0355 - P0359: Testing and Inspection P0356
For diagnosis of code P0356 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 262
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 263
P0355 - P0359: Testing and Inspection P0357
For diagnosis of code P0357 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 264
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 265
P0355 - P0359: Testing and Inspection P0358
For diagnosis of code P0358 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 266
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 267
P0355 - P0359: Testing and Inspection P0359
For diagnosis of code P0359 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0355 - P0359,
( P0356 P0357 P0358 0355 0356 0357 0358 0359 ) > System Information > System Diagnosis > P0355 > Page 268
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364,
( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis
P0360 - P0364: Testing and Inspection
For diagnosis of code P0360 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0300-P03ZZ > P0360 - P0364,
( P0361 P0362 P0363 0360 0361 0362 0363 0364 ) > System Information > System Diagnosis > Page 272
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400
P0400 - P0404: Testing and Inspection P0400
For diagnosis of code P0400 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 278
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 279
P0400 - P0404: Testing and Inspection P0401
For diagnosis of code P0401 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 280
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 281
P0400 - P0404: Testing and Inspection P0402
For diagnosis of code P0402 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 282
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 283
P0400 - P0404: Testing and Inspection P0403
For diagnosis of code P0403 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0400 - P0404,
( P0401 P0402 P0403 0400 0401 0402 0403 0404 ) > System Information > System Diagnosis > P0400 > Page 284
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414,
( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411
P0410 - P0414: Testing and Inspection P0411
For diagnosis of code P0411 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414,
( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 289
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414,
( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 290
P0410 - P0414: Testing and Inspection P0412
For diagnosis of code P0412 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0410 - P0414,
( P0411 P0412 P0413 0410 0411 0412 0413 0414 ) > System Information > System Diagnosis > P0411 > Page 291
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424,
( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis
P0420 - P0424: Testing and Inspection
For diagnosis of code P0420 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0420 - P0424,
( P0421 P0422 P0423 0420 0421 0422 0423 0424 ) > System Information > System Diagnosis > Page 295
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434,
( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis
P0430 - P0434: Testing and Inspection
For diagnosis of code P0430 refer to chart
P0305 - P0442
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0430 - P0434,
( P0431 P0432 P0433 0430 0431 0432 0433 0434 ) > System Information > System Diagnosis > Page 299
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444,
( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442
P0440 - P0444: Testing and Inspection P0442
For diagnosis of code P0442 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information , See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444,
( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 304
P0440 - P0444: Testing and Inspection P0443
For diagnosis of code P0443 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0440 - P0444,
( P0441 P0442 P0443 0440 0441 0442 0443 0444 ) > System Information > System Diagnosis > P0442 > Page 305
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451
P0450 - P0454: Testing and Inspection P0451
For diagnosis of code P0451 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 310
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 311
P0450 - P0454: Testing and Inspection P0452
For diagnosis of code P0452 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 312
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 313
P0450 - P0454: Testing and Inspection P0453
For diagnosis of code P0453 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0450 - P0454,
( P0451 P0452 P0453 0450 0451 0452 0453 0454 ) > System Information > System Diagnosis > P0451 > Page 314
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459,
( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455
P0455 - P0459: Testing and Inspection P0455
For diagnosis of code P0455 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information , See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459,
( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 319
P0455 - P0459: Testing and Inspection P0457
For diagnosis of code P0457 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0455 - P0459,
( P0456 P0457 P0458 0455 0456 0457 0458 0459 ) > System Information > System Diagnosis > P0455 > Page 320
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464,
( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460
P0460 - P0464: Testing and Inspection P0460
For diagnosis of code P0460 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464,
( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 325
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464,
( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 326
P0460 - P0464: Testing and Inspection P0461
For diagnosis of code P0461 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0400-P04ZZ > P0460 - P0464,
( P0461 P0462 P0463 0460 0461 0462 0463 0464 ) > System Information > System Diagnosis > P0460 > Page 327
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500
P0500 - P0504: Testing and Inspection P0500
For diagnosis of P0500 refer to system experiencing problems.
Engine Control System or Transmission Control System
P0443 - P071x
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 333
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control System diagnostic information, See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Wiper and Washer Systems
Part 1 Of 5
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Wiper and Washer system diagnostic information, See: Wiper and Washer
Systems/Testing and Inspection
Transfer Case
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 334
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 335
P0500 - P0504: Testing and Inspection P0501
For diagnosis of code P0501 refer to chart
P0443 - P071x
NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform
complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 336
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 337
P0500 - P0504: Testing and Inspection P0503
For diagnosis of code P0503 refer to chart
P0443 - P071x
NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform
complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0500 - P0504,
( P0501 P0502 P0503 0500 0501 0502 0503 0504 ) > System Information > System Diagnosis > P0500 > Page 338
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509,
( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis
P0505 - P0509: Testing and Inspection
For diagnosis of code P0505 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0505 - P0509,
( P0506 P0507 P0508 0505 0506 0507 0508 0509 ) > System Information > System Diagnosis > Page 342
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554,
( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552
P0550 - P0554: Testing and Inspection P0552
For diagnosis of code P0552 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554,
( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 347
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554,
( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 348
P0550 - P0554: Testing and Inspection P0553
For diagnosis of code P0553 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0500-P05ZZ > P0550 - P0554,
( P0551 P0552 P0553 0550 0551 0552 0553 0554 ) > System Information > System Diagnosis > P0552 > Page 349
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602
P0600 - P0604: Testing and Inspection P0602
For diagnosis of code P0602 refer to chart
P0443 - P071x
NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to VID Block Procedure.
See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 355
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 356
P0600 - P0604: Testing and Inspection P0603
For diagnosis of code P0603 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0600 - P0604,
( P0601 P0602 P0603 0600 0601 0602 0603 0604 ) > System Information > System Diagnosis > P0602 > Page 357
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609,
( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis
P0605 - P0609: Testing and Inspection
For diagnosis of code P0605 refer to chart
P0443 - P071x
NOTE 14: Be sure to check for aftermarket performance products before replacing PCM. If
replacement is necessary refer to Flash Electrically Erasable Programmable Read Only Memory
(EEPROM), See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0600-P06ZZ > P0605 - P0609,
( P0606 P0607 P0608 0605 0606 0607 0608 0609 ) > System Information > System Diagnosis > Page 361
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704,
( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703
P0700 - P0704: Testing and Inspection P0703
For diagnosis of code P0703 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704,
( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 367
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704,
( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 368
P0700 - P0704: Testing and Inspection P0704
For diagnosis of code P0704 refer to chart
P0443 - P071x
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0700 - P0704,
( P0701 P0702 P0703 0700 0701 0702 0703 0704 ) > System Information > System Diagnosis > P0703 > Page 369
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709,
( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705
P0705 - P0709: Testing and Inspection P0705
For diagnosis of code P0705 refer to chart
P0705-P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709,
( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 374
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709,
( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 375
P0705 - P0709: Testing and Inspection P0708
For diagnosis of code P0708 refer to chart
P0705-P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0705 - P0709,
( P0706 P0707 P0708 0705 0706 0707 0708 0709 ) > System Information > System Diagnosis > P0705 > Page 376
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714,
( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712
P0710 - P0714: Testing and Inspection P0712
For diagnosis of code P0712 refer to chart
P0712-P1780
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714,
( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 381
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714,
( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 382
P0710 - P0714: Testing and Inspection P0713
For diagnosis of code P0713 refer to chart
P0712-P1780
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0710 - P0714,
( P0711 P0712 P0713 0710 0711 0712 0713 0714 ) > System Information > System Diagnosis > P0712 > Page 383
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719,
( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis
P0715 - P0719: Testing and Inspection
For diagnosis of code P0715 refer to chart
P0712-P1780
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0715 - P0719,
( P0716 P0717 P0718 0715 0716 0717 0718 0719 ) > System Information > System Diagnosis > Page 387
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission
P0720 - P0724: Testing and Inspection Manual Transmission
For diagnosis of code P072x refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission >
Page 392
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Note: "x" = any number 0 thru 9
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission >
Page 393
P0720 - P0724: Testing and Inspection Automatic Transmission
P0720
For diagnosis of code P0720 refer to chart
P0720-P1740
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission >
Page 394
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
P0721
For diagnosis of code P0721 refer to chart
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission >
Page 395
P0720-P1740
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0720 - P0724,
( P0721 P0722 P0723 0720 0721 0722 0723 0724 ) > System Information > System Diagnosis > Manual Transmission >
Page 396
-
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729,
( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis
P0725 - P0729: Testing and Inspection
For diagnosis of code P072x refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0725 - P0729,
( P0726 P0727 P0728 0725 0726 0727 0728 0729 ) > System Information > System Diagnosis > Page 400
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Note: "x" = any number 0 thru 9
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731
P0730 - P0734: Testing and Inspection P0731
For diagnosis of code P0731 refer to chart
P0731-P1703
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 405
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 406
P0730 - P0734: Testing and Inspection P0732
For diagnosis of code P0732 refer to chart
P0731-P1703
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 407
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 408
P0730 - P0734: Testing and Inspection P0733
For diagnosis of code P0733 refer to chart
P0733-P0755
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 409
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 410
P0730 - P0734: Testing and Inspection P0734
For diagnosis of code P0734 refer to chart
P0733-P0755
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0730 - P0734,
( P0731 P0732 P0733 0730 0731 0732 0733 0734 ) > System Information > System Diagnosis > P0731 > Page 411
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739,
( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis
P0735 - P0739: Testing and Inspection
For diagnosis of code P0735 refer to chart
P0720-P1740
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0735 - P0739,
( P0736 P0737 P0738 0735 0736 0737 0738 0739 ) > System Information > System Diagnosis > Page 415
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744,
( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741
P0740 - P0744: Testing and Inspection P0741
For diagnosis of code P0741 refer to chart
P0712-P1780
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744,
( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 420
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744,
( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 421
P0740 - P0744: Testing and Inspection P0743
For diagnosis of code P0743 refer to chart
P0712-P1780
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0740 - P0744,
( P0741 P0742 P0743 0740 0741 0742 0743 0744 ) > System Information > System Diagnosis > P0741 > Page 422
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754,
( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis
P0750 - P0754: Testing and Inspection
For diagnosis of code P0750 refer to chart
P0733-P0755
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0750 - P0754,
( P0751 P0752 P0753 0750 0751 0752 0753 0754 ) > System Information > System Diagnosis > Page 426
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759,
( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis
P0755 - P0759: Testing and Inspection
For diagnosis of code P0755 refer to chart
P0733-P0755
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0755 - P0759,
( P0756 P0757 P0758 0755 0756 0757 0758 0759 ) > System Information > System Diagnosis > Page 430
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764,
( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis
P0760 - P0764: Testing and Inspection
For diagnosis of code P0760 refer to chart
P0705-P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0760 - P0764,
( P0761 P0762 P0763 0760 0761 0762 0763 0764 ) > System Information > System Diagnosis > Page 434
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769,
( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis
P0765 - P0769: Testing and Inspection
For diagnosis of code P0765 refer to chart
P0720-P1740
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0700-P07ZZ > P0765 - P0769,
( P0766 P0767 P0768 0765 0766 0767 0768 0769 ) > System Information > System Diagnosis > Page 438
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814,
( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis
P0810 - P0814: Testing and Inspection
For diagnosis of code P0812 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P0800-P08ZZ > P0810 - P0814,
( P0811 P0812 P0813 0810 0811 0812 0813 0814 ) > System Information > System Diagnosis > Page 443
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004,
( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000
P1000 - P1004: Testing and Inspection P1000
For diagnosis of code P1000 refer to chart
P072x - P1138
NOTE 1: DTC P1000 is ignored in KOEO and KOER Self-Test. Disregard the DTC P1000 and
continue as directed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004,
( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 449
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004,
( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 450
P1000 - P1004: Testing and Inspection P1001
For diagnosis of code P1001 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1000-P10ZZ > P1000 - P1004,
( P1001 P1002 P1003 1000 1001 1002 1003 1004 ) > System Information > System Diagnosis > P1000 > Page 451
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104,
( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100
P1100 - P1104: Testing and Inspection P1100
For diagnosis of code P1100 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104,
( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 457
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104,
( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 458
P1100 - P1104: Testing and Inspection P1101
For diagnosis of code P1101 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1100 - P1104,
( P1101 P1102 P1103 1100 1101 1102 1103 1104 ) > System Information > System Diagnosis > P1100 > Page 459
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112
P1110 - P1114: Testing and Inspection P1112
For diagnosis of code P1112 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 464
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 465
P1110 - P1114: Testing and Inspection P1114
For diagnosis of code P1114 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1110 - P1114,
( P1111 P1112 P1113 1110 1111 1112 1113 1114 ) > System Information > System Diagnosis > P1112 > Page 466
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115
P1115 - P1119: Testing and Inspection P1115
For diagnosis of code P1115 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 471
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 472
P1115 - P1119: Testing and Inspection P1116
For diagnosis of code P1116 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 473
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 474
P1115 - P1119: Testing and Inspection P1117
For diagnosis of code P1117 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1115 - P1119,
( P1116 P1117 P1118 1115 1116 1117 1118 1119 ) > System Information > System Diagnosis > P1115 > Page 475
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120
P1120 - P1124: Testing and Inspection P1120
For diagnosis of code P1120 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 480
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 481
P1120 - P1124: Testing and Inspection P1121
For diagnosis of code P1121 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 482
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 483
P1120 - P1124: Testing and Inspection P1124
For diagnosis of code P1124 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1120 - P1124,
( P1121 P1122 P1123 1120 1121 1122 1123 1124 ) > System Information > System Diagnosis > P1120 > Page 484
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125
P1125 - P1129: Testing and Inspection P1125
For diagnosis of code P1125 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 489
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 490
P1125 - P1129: Testing and Inspection P1127
For diagnosis of code P1127 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 491
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 492
P1125 - P1129: Testing and Inspection P1128
For diagnosis of code P1128 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 493
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 494
P1125 - P1129: Testing and Inspection P1129
For diagnosis of code P1129 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1125 - P1129,
( P1126 P1127 P1128 1125 1126 1127 1128 1129 ) > System Information > System Diagnosis > P1125 > Page 495
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130
P1130 - P1134: Testing and Inspection P1130
For diagnosis of code P1130 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 500
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 501
P1130 - P1134: Testing and Inspection P1131
For diagnosis of code P1131 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 502
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 503
P1130 - P1134: Testing and Inspection P1132
For diagnosis of code P1132 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1130 - P1134,
( P1131 P1132 P1133 1130 1131 1132 1133 1134 ) > System Information > System Diagnosis > P1130 > Page 504
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139,
( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137
P1135 - P1139: Testing and Inspection P1137
For diagnosis of code P1137 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139,
( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 509
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139,
( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 510
P1135 - P1139: Testing and Inspection P1138
For diagnosis of code P1138 refer to chart
P072x - P1138
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1135 - P1139,
( P1136 P1137 P1138 1135 1136 1137 1138 1139 ) > System Information > System Diagnosis > P1137 > Page 511
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150
P1150 - P1154: Testing and Inspection P1150
For diagnosis of code P1150 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 516
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 517
P1150 - P1154: Testing and Inspection P1151
For diagnosis of code P1151 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 518
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 519
P1150 - P1154: Testing and Inspection P1152
For diagnosis of code P1152 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1150 - P1154,
( P1151 P1152 P1153 1150 1151 1152 1153 1154 ) > System Information > System Diagnosis > P1150 > Page 520
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159,
( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157
P1155 - P1159: Testing and Inspection P1157
For diagnosis of code P1157 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159,
( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 525
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159,
( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 526
P1155 - P1159: Testing and Inspection P1158
For diagnosis of code P1158 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1155 - P1159,
( P1156 P1157 P1158 1155 1156 1157 1158 1159 ) > System Information > System Diagnosis > P1157 > Page 527
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169,
( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168
P1165 - P1169: Testing and Inspection P1168
For diagnosis of code P1168 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169,
( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 532
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169,
( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 533
P1165 - P1169: Testing and Inspection P1169
For diagnosis of code P1169 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1165 - P1169,
( P1166 P1167 P1168 1165 1166 1167 1168 1169 ) > System Information > System Diagnosis > P1168 > Page 534
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180
P1180 - P1184: Testing and Inspection P1180
For diagnosis of code P1180 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 539
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 540
P1180 - P1184: Testing and Inspection P1181
For diagnosis of code P1181 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 541
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 542
P1180 - P1184: Testing and Inspection P1183
For diagnosis of code P1183 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 543
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 544
P1180 - P1184: Testing and Inspection P1184
For diagnosis of code P1184 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1100-P11ZZ > P1180 - P1184,
( P1181 P1182 P1183 1180 1181 1182 1183 1184 ) > System Information > System Diagnosis > P1180 > Page 545
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229,
( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis
P1225 - P1229: Testing and Inspection
For diagnosis of code P1229 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1225 - P1229,
( P1226 P1227 P1228 1225 1226 1227 1228 1229 ) > System Information > System Diagnosis > Page 550
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232
P1230 - P1234: Testing and Inspection P1232
For diagnosis of code P1232 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 555
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 556
P1230 - P1234: Testing and Inspection P1233
For diagnosis of code P1233 refer to chart
P1150 - P1401
NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 557
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 558
P1230 - P1234: Testing and Inspection P1234
For diagnosis of code P1234 refer to chart
P1150 - P1401
NOTE 10: Perform Rear Electronics Module (REM) self-test/diagnostics.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1230 - P1234,
( P1231 P1232 P1233 1230 1231 1232 1233 1234 ) > System Information > System Diagnosis > P1232 > Page 559
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235
P1235 - P1239: Testing and Inspection P1235
For diagnosis of code P1235 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 564
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 565
P1235 - P1239: Testing and Inspection P1236
For diagnosis of code P1236 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 566
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 567
P1235 - P1239: Testing and Inspection P1237
For diagnosis of code P1237 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 568
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 569
P1235 - P1239: Testing and Inspection P1238
For diagnosis of code P1238 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1235 - P1239,
( P1236 P1237 P1238 1235 1236 1237 1238 1239 ) > System Information > System Diagnosis > P1235 > Page 570
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244,
( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis
P1240 - P1244: Testing and Inspection
For diagnosis of code P1244 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1240 - P1244,
( P1241 P1242 P1243 1240 1241 1242 1243 1244 ) > System Information > System Diagnosis > Page 574
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249,
( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245
P1245 - P1249: Testing and Inspection P1245
For diagnosis of code P1245 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249,
( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 579
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249,
( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 580
P1245 - P1249: Testing and Inspection P1246
For diagnosis of code P1246 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1245 - P1249,
( P1246 P1247 P1248 1245 1246 1247 1248 1249 ) > System Information > System Diagnosis > P1245 > Page 581
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis
P1260 - P1264: Testing and Inspection
For diagnosis of code P1260 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1260 - P1264,
( P1261 P1262 P1263 1260 1261 1262 1263 1264 ) > System Information > System Diagnosis > Page 585
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis
P1270 - P1274: Testing and Inspection
For diagnosis of code P1270 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1270 - P1274,
( P1271 P1272 P1273 1270 1271 1272 1273 1274 ) > System Information > System Diagnosis > Page 589
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285
P1285 - P1289: Testing and Inspection P1285
For diagnosis of code P1285 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 594
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 595
P1285 - P1289: Testing and Inspection P1288
For diagnosis of code P1288 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 596
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 597
P1285 - P1289: Testing and Inspection P1289
For diagnosis of code P1289 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1285 - P1289,
( P1286 P1287 P1288 1285 1286 1287 1288 1289 ) > System Information > System Diagnosis > P1285 > Page 598
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294,
( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis
P1290 - P1294: Testing and Inspection
For diagnosis of code P1290 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1290 - P1294,
( P1291 P1292 P1293 1290 1291 1292 1293 1294 ) > System Information > System Diagnosis > Page 602
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299,
( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis
P1295 - P1299: Testing and Inspection
For diagnosis of code P1299 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1200-P12ZZ > P1295 - P1299,
( P1296 P1297 P1298 1295 1296 1297 1298 1299 ) > System Information > System Diagnosis > Page 606
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309,
( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis
P1305 - P1309: Testing and Inspection
For diagnosis of code P1309 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1305 - P1309,
( P1306 P1307 P1308 1305 1306 1307 1308 1309 ) > System Information > System Diagnosis > Page 611
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380
P1380 - P1384: Testing and Inspection P1380
For diagnosis of code P1380 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 616
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 617
P1380 - P1384: Testing and Inspection P1381
For diagnosis of code P1381 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 618
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 619
P1380 - P1384: Testing and Inspection P1383
For diagnosis of code P1383 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1300-P13ZZ > P1380 - P1384,
( P1381 P1382 P1383 1380 1381 1382 1383 1384 ) > System Information > System Diagnosis > P1380 > Page 620
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404,
( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400
P1400 - P1404: Testing and Inspection P1400
For diagnosis of code P1400 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404,
( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 626
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404,
( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 627
P1400 - P1404: Testing and Inspection P1401
For diagnosis of code P1401 refer to chart
P1150 - P1401
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1400 - P1404,
( P1401 P1402 P1403 1400 1401 1402 1403 1404 ) > System Information > System Diagnosis > P1400 > Page 628
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405
P1405 - P1409: Testing and Inspection P1405
For diagnosis of code P1405 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 633
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 634
P1405 - P1409: Testing and Inspection P1406
For diagnosis of code P1406 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 635
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 636
P1405 - P1409: Testing and Inspection P1408
For diagnosis of code P1408 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 637
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 638
P1405 - P1409: Testing and Inspection P1409
For diagnosis of code P1409 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1405 - P1409,
( P1406 P1407 P1408 1405 1406 1407 1408 1409 ) > System Information > System Diagnosis > P1405 > Page 639
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414,
( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413
P1410 - P1414: Testing and Inspection P1413
For diagnosis of code P1413 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414,
( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 644
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414,
( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 645
P1410 - P1414: Testing and Inspection P1414
For diagnosis of code P1414 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1410 - P1414,
( P1411 P1412 P1413 1410 1411 1412 1413 1414 ) > System Information > System Diagnosis > P1413 > Page 646
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434,
( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis
P1430 - P1434: Testing and Inspection
For diagnosis of code P1432 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1430 - P1434,
( P1431 P1432 P1433 1430 1431 1432 1433 1434 ) > System Information > System Diagnosis > Page 650
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1440 - P1444,
( P1441 P1442 P1443 1440 1441 1442 1443 1444 ) > System Information > System Diagnosis
P1440 - P1444: Testing and Inspection
For diagnosis of code P1443 refer to chart
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information , See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454,
( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450
P1450 - P1454: Testing and Inspection P1450
For diagnosis of code P1450 refer to the system experiencing the problem.
Computers and Control Systems
P1405 - P1517
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454,
( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 658
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Evaporative Emissions System
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Evaporative Emissions diagnostic information, See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454,
( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 659
P1450 - P1454: Testing and Inspection P1451
For diagnosis of code P1451 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1450 - P1454,
( P1451 P1452 P1453 1450 1451 1452 1453 1454 ) > System Information > System Diagnosis > P1450 > Page 660
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460
P1460 - P1464: Testing and Inspection P1460
For diagnosis of code P1460 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 665
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 666
P1460 - P1464: Testing and Inspection P1461
For diagnosis of code P1461 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 667
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 668
P1460 - P1464: Testing and Inspection P1462
For diagnosis of code P1462 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 669
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 670
P1460 - P1464: Testing and Inspection P1463
For diagnosis of code P1463 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 671
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 672
P1460 - P1464: Testing and Inspection P1464
For diagnosis of P1464 refer to the system experiencing the problem.
Computers and Control Systems
P1405 - P1517
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1460 - P1464,
( P1461 P1462 P1463 1460 1461 1462 1463 1464 ) > System Information > System Diagnosis > P1460 > Page 673
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Heating and Air Conditioning
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete Heating and Air Conditioning system diagnostic information, See: Heating and Air
Conditioning/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469,
( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis
P1465 - P1469: Testing and Inspection
For diagnosis of code P1469 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1465 - P1469,
( P1466 P1467 P1468 1465 1466 1467 1468 1469 ) > System Information > System Diagnosis > Page 677
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474,
( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis
P1470 - P1474: Testing and Inspection
For diagnosis of code P1474 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1470 - P1474,
( P1471 P1472 P1473 1470 1471 1472 1473 1474 ) > System Information > System Diagnosis > Page 681
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477
P1475 - P1479: Testing and Inspection P1477
For diagnosis of code P1477 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 686
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 687
P1475 - P1479: Testing and Inspection P1479
For diagnosis of code P1479 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1400-P14ZZ > P1475 - P1479,
( P1476 P1477 P1478 1475 1476 1477 1478 1479 ) > System Information > System Diagnosis > P1477 > Page 688
- Or information published by the manufacturer for this vehicle did not include this code
For complete Engine Control diagnostic information , See: Powertrain Management/Computers and
Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500
P1500 - P1504: Testing and Inspection P1500
For diagnosis of code P1500 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 694
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 695
P1500 - P1504: Testing and Inspection P1501
For diagnosis of code P1501 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 696
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 697
P1500 - P1504: Testing and Inspection P1502
For diagnosis of code P1502 refer to chart
P1405 - P1517
NOTE 12: Vehicle Speed information is provided by the Antilock Brake System (ABS). Perform
complete diagnosis, See: Brakes and Traction Control/Antilock Brakes / Traction Control
Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 698
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 699
P1500 - P1504: Testing and Inspection P1504
For diagnosis of code P1504 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1500 - P1504,
( P1501 P1502 P1503 1500 1501 1502 1503 1504 ) > System Information > System Diagnosis > P1500 > Page 700
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509,
( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506
P1505 - P1509: Testing and Inspection P1506
For diagnosis of code P1506 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509,
( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 705
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509,
( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 706
P1505 - P1509: Testing and Inspection P1507
For diagnosis of code P1507 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1505 - P1509,
( P1506 P1507 P1508 1505 1506 1507 1508 1509 ) > System Information > System Diagnosis > P1506 > Page 707
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516
P1515 - P1519: Testing and Inspection P1516
For diagnosis of code P1516 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 712
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 713
P1515 - P1519: Testing and Inspection P1517
For diagnosis of code P1517 refer to chart
P1405 - P1517
If there is no link in the chart then:
- This code is not a valid code for this vehicle
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 714
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 715
P1515 - P1519: Testing and Inspection P1518
For diagnosis of code P1518 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 716
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 717
P1515 - P1519: Testing and Inspection P1519
For diagnosis of code P1519 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1515 - P1519,
( P1516 P1517 P1518 1515 1516 1517 1518 1519 ) > System Information > System Diagnosis > P1516 > Page 718
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524,
( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis
P1520 - P1524: Testing and Inspection
For diagnosis of code P1520 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1520 - P1524,
( P1521 P1522 P1523 1520 1521 1522 1523 1524 ) > System Information > System Diagnosis > Page 722
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549,
( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis
P1545 - P1549: Testing and Inspection
For diagnosis of code P1549 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1545 - P1549,
( P1546 P1547 P1548 1545 1546 1547 1548 1549 ) > System Information > System Diagnosis > Page 726
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554,
( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis
P1550 - P1554: Testing and Inspection
For diagnosis of code P1550 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1550 - P1554,
( P1551 P1552 P1553 1550 1551 1552 1553 1554 ) > System Information > System Diagnosis > Page 730
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574,
( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis
P1570 - P1574: Testing and Inspection
For diagnosis of code P1572 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1500-P15ZZ > P1570 - P1574,
( P1571 P1572 P1573 1570 1571 1572 1573 1574 ) > System Information > System Diagnosis > Page 734
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609,
( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis
P1605 - P1609: Testing and Inspection
For diagnosis of code P1605 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1605 - P1609,
( P1606 P1607 P1608 1605 1606 1607 1608 1609 ) > System Information > System Diagnosis > Page 739
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634,
( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis
P1630 - P1634: Testing and Inspection
For diagnosis of code P1633 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1630 - P1634,
( P1631 P1632 P1633 1630 1631 1632 1633 1634 ) > System Information > System Diagnosis > Page 743
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635
P1635 - P1639: Testing and Inspection P1635
For diagnosis of code P1635 refer to chart
P1518 - P1781
NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block
procedure, See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 748
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 749
P1635 - P1639: Testing and Inspection P1636
For diagnosis of code P1636 refer to chart
P1518 - P1781
NOTE 18: DTC P1636 indicates the PCM has lost communication with the Inductive Signature
Chip. Replace PCM. If replacement is necessary refer to Flash Electically Erasable Programmable
Read Only Memory (EEPROM), See: Powertrain Management/Computers and Control
Systems/Testing and Inspection/Programming and Relearning
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 750
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 751
P1635 - P1639: Testing and Inspection P1639
For diagnosis of code P1639 refer to chart
P1518 - P1781
NOTE 11: The vehicle ID block (VID) needs to be reprogrammed. Refer to Flash VID Block
procedure, See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Programming and Relearning
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1635 - P1639,
( P1636 P1637 P1638 1635 1636 1637 1638 1639 ) > System Information > System Diagnosis > P1635 > Page 752
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644,
( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis
P1640 - P1644: Testing and Inspection
For diagnosis of code P1641 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1640 - P1644,
( P1641 P1642 P1643 1640 1641 1642 1643 1644 ) > System Information > System Diagnosis > Page 756
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654,
( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650
P1650 - P1654: Testing and Inspection P1650
For diagnosis of code P1650 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654,
( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 761
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654,
( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 762
P1650 - P1654: Testing and Inspection P1651
For diagnosis of code P1651 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1600-P16ZZ > P1650 - P1654,
( P1651 P1652 P1653 1650 1651 1652 1653 1654 ) > System Information > System Diagnosis > P1650 > Page 763
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701
P1700 - P1704: Testing and Inspection P1701
For diagnosis of code P1701 refer to chart
P0705-P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 769
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 770
P1700 - P1704: Testing and Inspection P1702
For diagnosis of code P1702 refer to chart
P1702-P1900
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 771
P1700 - P1704: Testing and Inspection P1703
For diagnosis of code P1703 refer to charts
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 772
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 773
P1700 - P1704: Testing and Inspection P1704
For diagnosis of code P1704 refer to chart
P0102-P1705
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1700 - P1704,
( P1701 P1702 P1703 1700 1701 1702 1703 1704 ) > System Information > System Diagnosis > P1701 > Page 774
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705
P1705 - P1709: Testing and Inspection P1705
Manual Transmission
For diagnosis of code P1705 refer to chart
P1518 - P1781
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 779
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Automatic Transmission
For diagnosis of code P1705 refer to chart
P0102-P1705
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 780
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 781
P1705 - P1709: Testing and Inspection P1709
For diagnosis of code P1709 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1705 - P1709,
( P1706 P1707 P1708 1705 1706 1707 1708 1709 ) > System Information > System Diagnosis > P1705 > Page 782
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713
P1710 - P1714: Testing and Inspection P1713
For diagnosis of code P1713 refer to chart
P1702-P1900
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 > Page 787
P1710 - P1714: Testing and Inspection P1714
For diagnosis of code P1714 refer to chart
P0705-P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1710 - P1714,
( P1711 P1712 P1713 1710 1711 1712 1713 1714 ) > System Information > System Diagnosis > P1713 > Page 788
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715
P1715 - P1719: Testing and Inspection P1715
For diagnosis of code P1715 refer to chart
P0720-P1740
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 793
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 794
P1715 - P1719: Testing and Inspection P1716
For diagnosis of code P1716 refer to chart
P0720-P1740
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 795
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 796
P1715 - P1719: Testing and Inspection P1717
For diagnosis of code P1717 refer to chart
P0720-P1740
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 797
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1715 - P1719,
( P1716 P1717 P1718 1715 1716 1717 1718 1719 ) > System Information > System Diagnosis > P1715 > Page 798
P1715 - P1719: Testing and Inspection P1718
For diagnosis of code P1718 refer to chart
P1702-P1900
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729,
( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis
P1725 - P1729: Testing and Inspection
For diagnosis of code P1729 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1725 - P1729,
( P1726 P1727 P1728 1725 1726 1727 1728 1729 ) > System Information > System Diagnosis > Page 802
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744,
( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis
P1740 - P1744: Testing and Inspection
For diagnosis of code P1740 refer to chart
P0720-P1740
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1740 - P1744,
( P1741 P1742 P1743 1740 1741 1742 1743 1744 ) > System Information > System Diagnosis > Page 806
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749,
( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746
P1745 - P1749: Testing and Inspection P1746
For diagnosis of code P1746 refer to chart
P0705-P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749,
( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 811
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749,
( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 812
P1745 - P1749: Testing and Inspection P1747
For diagnosis of code P1747 refer to chart
P0712-P1780
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1745 - P1749,
( P1746 P1747 P1748 1745 1746 1747 1748 1749 ) > System Information > System Diagnosis > P1746 > Page 813
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764,
( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1763
P1760 - P1764: Testing and Inspection P1763
For diagnosis of code P1763 refer to chart
Part 4 Of 5
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764,
( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1763 > Page 818
For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and
Warning Indicators/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764,
( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1763 > Page 819
P1760 - P1764: Testing and Inspection P1764
For diagnosis of code P1764 refer to chart
Part 4 Of 5
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1760 - P1764,
( P1761 P1762 P1763 1760 1761 1762 1763 1764 ) > System Information > System Diagnosis > P1763 > Page 820
For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and
Warning Indicators/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780
P1780 - P1784: Testing and Inspection P1780
For diagnosis of code P1780 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 825
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 826
P1780 - P1784: Testing and Inspection P1781
For diagnosis of code P1781 refer to chart
P1518 - P1781
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 827
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 828
P1780 - P1784: Testing and Inspection P1783
For diagnosis of code P1783 refer to chart
P0712-P1780
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1700-P17ZZ > P1780 - P1784,
( P1781 P1782 P1783 1780 1781 1782 1783 1784 ) > System Information > System Diagnosis > P1780 > Page 829
Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1800 - P1804,
( P1801 P1802 P1803 1800 1801 1802 1803 1804 ) > System Information > System Diagnosis
P1800 - P1804: Testing and Inspection
For diagnosis of code P1804 refer to the system experiencing the problem
Instrument Panel
Part 4 Of 5
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
-
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1800 - P1804,
( P1801 P1802 P1803 1800 1801 1802 1803 1804 ) > System Information > System Diagnosis > Page 834
For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and
Warning Indicators/Testing and Inspection
Transfer Case
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809,
( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806
P1805 - P1809: Testing and Inspection P1806
For diagnosis of code P1806 refer to the system experiencing the problem
Instrument Panel
Part 4 Of 5
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809,
( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 > Page 839
-
For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and
Warning Indicators/Testing and Inspection
Transfer Case
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809,
( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 > Page 840
P1805 - P1809: Testing and Inspection P1808
For diagnosis of code P1808 refer to the system experiencing the problem
Instrument Panel
Part 4 Of 5
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1805 - P1809,
( P1806 P1807 P1808 1805 1806 1807 1808 1809 ) > System Information > System Diagnosis > P1806 > Page 841
-
For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and
Warning Indicators/Testing and Inspection
Transfer Case
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1810 - P1814,
( P1811 P1812 P1813 1810 1811 1812 1813 1814 ) > System Information > System Diagnosis > P1810
P1810 - P1814: Testing and Inspection P1810
For diagnosis of code P1810 refer to the system experiencing the problem
Instrument Panel
Part 4 Of 5
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1810 - P1814,
( P1811 P1812 P1813 1810 1811 1812 1813 1814 ) > System Information > System Diagnosis > P1810 > Page 846
-
For complete Instrument Panel diagnostic information, See: Instrument Panel, Gauges and
Warning Indicators/Testing and Inspection
Transfer Case
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1810 - P1814,
( P1811 P1812 P1813 1810 1811 1812 1813 1814 ) > System Information > System Diagnosis > P1810 > Page 847
P1810 - P1814: Testing and Inspection P1812
For diagnosis of code P1812 refer to chart
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1815 - P1819,
( P1816 P1817 P1818 1815 1816 1817 1818 1819 ) > System Information > System Diagnosis
P1815 - P1819: Testing and Inspection
For diagnosis of code P1815 refer to chart
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824,
( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820
P1820 - P1824: Testing and Inspection P1820
For diagnosis of code P1820 refer to chart
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824,
( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 > Page 855
P1820 - P1824: Testing and Inspection P1822
For diagnosis of code P1822 refer to chart
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1820 - P1824,
( P1821 P1822 P1823 1820 1821 1822 1823 1824 ) > System Information > System Diagnosis > P1820 > Page 856
P1820 - P1824: Testing and Inspection P1824
For diagnosis of code P1824 refer to chart
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829,
( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826
P1825 - P1829: Testing and Inspection P1826
For diagnosis of code P1826 refer to chart
B2141-B2106 / P1763-P1826
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1825 - P1829,
( P1826 P1827 P1828 1825 1826 1827 1828 1829 ) > System Information > System Diagnosis > P1826 > Page 861
P1825 - P1829: Testing and Inspection P1828
For diagnosis of code P1828 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1830 - P1834,
( P1831 P1832 P1833 1830 1831 1832 1833 1834 ) > System Information > System Diagnosis
P1830 - P1834: Testing and Inspection
For diagnosis of code P1830 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839,
( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836
P1835 - P1839: Testing and Inspection P1836
For diagnosis of code P1836 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839,
( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836 > Page 869
P1835 - P1839: Testing and Inspection P1837
For diagnosis of code P1837 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1835 - P1839,
( P1836 P1837 P1838 1835 1836 1837 1838 1839 ) > System Information > System Diagnosis > P1836 > Page 870
P1835 - P1839: Testing and Inspection P1838
For diagnosis of code P1838 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1845 - P1849,
( P1846 P1847 P1848 1845 1846 1847 1848 1849 ) > System Information > System Diagnosis
P1845 - P1849: Testing and Inspection
For diagnosis of code P1846 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1850 - P1854,
( P1851 P1852 P1853 1850 1851 1852 1853 1854 ) > System Information > System Diagnosis > P1850
P1850 - P1854: Testing and Inspection P1850
For diagnosis of code P1850 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1850 - P1854,
( P1851 P1852 P1853 1850 1851 1852 1853 1854 ) > System Information > System Diagnosis > P1850 > Page 878
P1850 - P1854: Testing and Inspection P1854
For diagnosis of code P1854 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1855 - P1859,
( P1856 P1857 P1858 1855 1856 1857 1858 1859 ) > System Information > System Diagnosis
P1855 - P1859: Testing and Inspection
For diagnosis of code P1858 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869,
( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis > P1866
P1865 - P1869: Testing and Inspection P1866
For diagnosis of code P1866 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1865 - P1869,
( P1866 P1867 P1868 1865 1866 1867 1868 1869 ) > System Information > System Diagnosis > P1866 > Page 886
P1865 - P1869: Testing and Inspection P1867
For diagnosis of code P1867 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1870 - P1874,
( P1871 P1872 P1873 1870 1871 1872 1873 1874 ) > System Information > System Diagnosis
P1870 - P1874: Testing and Inspection
For diagnosis of code P1874 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1875 - P1879,
( P1876 P1877 P1878 1875 1876 1877 1878 1879 ) > System Information > System Diagnosis
P1875 - P1879: Testing and Inspection
For diagnosis of code P1875 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1800-P18ZZ > P1890 - P1894,
( P1891 P1892 P1893 1890 1891 1892 1893 1894 ) > System Information > System Diagnosis
P1890 - P1894: Testing and Inspection
For diagnosis of code P1891 refer to chart
P1828-P1891
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transfer Case, follow this link: See: Transmission and
Drivetrain/Transfer Case/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904,
( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission
P1900 - P1904: Testing and Inspection Manual Transmission
For diagnosis of code P1900 refer to charts
P1783 - P1900
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904,
( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission >
Page 901
-
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > P1900-P19ZZ > P1900 - P1904,
( P1901 P1902 P1903 1900 1901 1902 1903 1904 ) > System Information > System Diagnosis > Manual Transmission >
Page 902
P1900 - P1904: Testing and Inspection Automatic Transmission
For diagnosis of code P1900 refer to chart
P1702-P1900
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Transmission Control system, follow this link: See: Powertrain
Management/Transmission Control Systems/Testing and Inspection
If there is no link in the chart then:
- This code is not a valid code for this vehicle
- Or information published by the manufacturer for this vehicle did not include this code
For complete diagnosis of the Engine Control system, follow this link: See: Powertrain
Management/Computers and Control Systems/Testing and Inspection
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations
Accessory Delay Relay: Locations
The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay
Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory
Delay Module > Accessory Delay Relay > Component Information > Locations > Page 909
Accessory Delay Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations
Alarm Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations > Page 913
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Locations > Page 914
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 917
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 918
Alarm Module: Diagrams Remote Anti-Theft Personality Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 919
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 920
Alarm Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 921
Alarm Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm
Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 922
Alarm Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna
Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna
Control Module > Component Information > Locations > Page 926
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications
Multifunction Electronic Control Modules: Specifications
Remote Anti-Theft Personality Module 2.3-3.3 Nm
Battery Ground Cable Screws 7-10 Nm
GEM/CTM Screw 1.6-2.0 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 930
Multifunction Electronic Control Modules: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications > Page 931
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions
Multifunction Electronic Control Modules: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 934
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 935
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 936
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 937
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 938
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 939
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 940
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 941
Multifunction Electronic Control Modules: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 942
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 943
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 944
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 945
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 946
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 947
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 948
Multifunction Electronic Control Modules: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 949
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 950
Multifunction Electronic Control Modules: Electrical Diagrams
Diagram 59-1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 951
Diagram 59-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 952
Diagram 59-3
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 953
Diagram 59-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 954
Diagram 59-5
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Diagram
Information and Instructions > Page 955
Diagram 59-6
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 956
Multifunction Electronic Control Modules: Description and Operation
The multifunction modules consist of the following:
^ generic electronic module (GEM)/central timer module (CTM)
^ remote anti-theft personality (RAP) module
The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated
locks systems.
The GEM/CTM controls the following features:
^ wiper/washer (front/rear)
^ warning chime
^ battery saver
^ illuminated entry and courtesy lamps
^ driver one touch down power window (GEM only)
^ accessory delay
^ 4 wheel drive (GEM only)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page 957
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM)
Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic
(GEM)/Central Timer (CTM)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1 Remove the screw.
2 Disconnect the four connectors from the GEM/CTM.
3 Remove the GEM/CTM.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 960
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 961
Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft
Personality (RAP)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static
charges, damage may result.
2. Remove the LH rear quarter trim panel.
3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors.
4. Remove the two RAP module fasteners.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment >
Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair > Module Generic Electronic (GEM)/Central Timer (CTM) > Page 962
5. Remove the RAP module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 968
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 969
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 970
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 971
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 972
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 973
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 974
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 975
Keyless Entry Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 976
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 977
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 978
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 979
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 980
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 981
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Page 982
Keyless Entry Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Page 983
Keyless Entry Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Diagrams > Page 984
Keyless Entry Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Navigation
Module > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations
Parking Assist Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 991
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 992
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Parking
Assist Control Module > Component Information > Locations > Page 993
Parking Assist Control Module: Service and Repair
REMOVAL
1. Remove the jack storage panel.
2. Remove the parking aid module.
1 Disconnect the electrical connector.
2 Remove the screws.
3 Remove the parking aid module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1000
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1001
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1002
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1003
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1004
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1005
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1006
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1007
Keyless Entry Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1008
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1009
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1010
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1011
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1012
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1013
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 1014
Keyless Entry Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 1015
Keyless Entry Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 1016
Keyless Entry Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Locations > Page 1020
Power Door Lock Control Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Locations > Page 1021
Power Door Lock Control Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Control
Module > Component Information > Locations > Page 1022
Power Door Lock Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 1026
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 1027
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Testing and Inspection > Two Door Models
Power Door Lock Relay: Testing and Inspection Two Door Models
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Testing and Inspection > Two Door Models > Page 1030
Power Door Lock Relay: Testing and Inspection Four Door Models
Driver Door Unlock Relay
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Testing and Inspection > Two Door Models > Page 1031
Door Lock/Unlock Relays
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams
Power Seat Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Page 1035
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Service Precautions > Technician Safety Information
Power Seat Control Module: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Service Precautions > Technician Safety Information > Page 1038
Power Seat Control Module: Vehicle Damage Warnings
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Service Precautions > Page 1039
Power Seat Control Module: Service and Repair
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track,
Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Remove the Driver Seat Module (DSM).
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the DSM.
INSTALLATION
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Service Precautions > Page 1040
1. Install the DSM.
1 Connect the electrical connectors.
2 Position the DSM.
3 Install the screws.
2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the
restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Left > Page 1045
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Page 1046
Seat Heater Control Module: Service and Repair
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track,
Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Disconnect the heated seat module electrical connector.
4. Remove the heated seat module.
1 Release the clip.
2 Remove the heated seat module.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Page 1047
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
1. Install the heated seat module.
2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For
additional information, refer to Seat-Track, Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the
restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
Anti-lock brake control module bolts 1.8 - 1.9 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 1052
Electronic Brake Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 1053
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 1054
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 1055
Electronic Brake Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 1056
Electronic Brake Control Module: Service and Repair
Removal
1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration
information to the scan tool. This information needs
to be downloaded into the new module once installed.
Disconnect the battery ground cable.
2. Remove the hydraulic control unit bolts.
3. Disconnect the anti-lock brake control module electrical connectors.
4. Remove the anti-lock brake control module.
1 Remove the bolts.
2 Remove the control module.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 1057
1. CAUTION: Once the new module is installed, it is necessary to download the module
configuration information from the scan tool into the
module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay > Page 1063
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay > Page 1064
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay > Page 1065
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 1066
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 1067
Blower Motor Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Compressor Clutch Relay
Compressor Clutch Relay: Locations Compressor Clutch Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Compressor Clutch Relay > Page 1072
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Compressor Clutch Relay > Page 1073
Compressor Clutch Relay: Locations Compressor Cut-Off Relay
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Compressor Clutch Relay > Page 1074
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1075
Compressor Clutch Relay: Description and Operation
WIDE OPEN THROTTLE A/C CUT-OFF
The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally
open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)).
If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant
temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C
(WAC) output, closing the relay contacts and sending voltage to the A/C clutch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Page 1076
Compressor Clutch Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts
Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts
Article No. 02-8-5
04/29/02
CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS
COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY
FORD: 1998-2001 EXPLORER
MERCURY: 1998-2001 MOUNTAINEER
ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature
Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a
steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the
FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software
version of the EATC Module.
ACTION Update the software version or replace the EATC Module. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE,
XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update
the EATC module software. On all other modules, replace the EATC module with service part
YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for
removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC
module ID number (Engineering Part Number).
NGS Procedure for Identifying EATC Module ID Number
1. Select "Diagnostics".
2. Select "EATC".
3. Select "Module I.D".
NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have
been previously updated with this software will display "GO7H-BA".
NGS Procedure for Updating Software
1. Select "Service Bay Functions".
2. Select "EATC" from module list.
3. Select "Module Configuration".
4. Select "99-01 Explorer" or "99-01 Mountaineer".
Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and
display "Module Data Download Successfull". If the EATC module has been updated previously, or
the module is not one of the modules listed as being capable of being updated, NGS will display
"Can not update with the NGS". If the module is not capable of being updated, replace the module
with part number YL2Z-19980-AA as listed above.
Parts Block
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts
> Page 1085
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208000, 208100, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From
Floor Ducts
Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts
Article No. 02-8-5
04/29/02
CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS
COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY
FORD: 1998-2001 EXPLORER
MERCURY: 1998-2001 MOUNTAINEER
ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature
Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a
steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the
FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software
version of the EATC Module.
ACTION Update the software version or replace the EATC Module. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE,
XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update
the EATC module software. On all other modules, replace the EATC module with service part
YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for
removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC
module ID number (Engineering Part Number).
NGS Procedure for Identifying EATC Module ID Number
1. Select "Diagnostics".
2. Select "EATC".
3. Select "Module I.D".
NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have
been previously updated with this software will display "GO7H-BA".
NGS Procedure for Updating Software
1. Select "Service Bay Functions".
2. Select "EATC" from module list.
3. Select "Module Configuration".
4. Select "99-01 Explorer" or "99-01 Mountaineer".
Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and
display "Module Data Download Successfull". If the EATC module has been updated previously, or
the module is not one of the modules listed as being capable of being updated, NGS will display
"Can not update with the NGS". If the module is not capable of being updated, replace the module
with part number YL2Z-19980-AA as listed above.
Parts Block
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From
Floor Ducts > Page 1091
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208000, 208100, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-21-3 > Oct > 00 > Climate Control - Blower
Control Service Tips
Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service
Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-21-3 > Oct > 00 > Climate Control - Blower
Control Service Tips > Page 1096
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 00-21-3 > Oct > 00 > Climate Control - Blower
Control Service Tips > Page 1097
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 >
Drivetrain - Front Drive Axle Vent Tube Fluid Leaks
Differential Cover: All Technical Service Bulletins Drivetrain - Front Drive Axle Vent Tube Fluid
Leaks
TSB 05-6-20
04/04/05
FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD
FORD: 1995-2001 Explorer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer
Sport Trac
MERCURY: 1997-2001 Mountaineer
This article supersedes TSB 03-05-08 to update the model year applications and to revise the
Service Procedure.
ISSUE Some Explorer/Mountaineer, Ranger and Explorer Sport/Sport Trac 4x4/AWD vehicles,
may exhibit a fluid leak from the front axle vent tube. This may be caused by fluid being thrown
toward the axle vent by the gears during vehicle operation.
ACTION Install a revised front axle cover kit. The revised cover has a baffle built in to reduce the
possibility of fluid being thrown out of the vent during vehicle operation. Refer to the following
Service Procedure.
SERVICE PROCEDURE
NOTE
DO NOT FOLLOW THE SERVICE PROCEDURE OUTLINED IN THE DANA/SPICER
INSTRUCTION SHEET INCLUDED IN THE COVER KIT. FOLLOW THE TSB SERVICE
PROCEDURE.
1. With the vehicle in NEUTRAL, raise and support the vehicle.
2. Remove the lower engine splash shield, if equipped.
3. Index-mark the front axle pinion flange and the front driveshaft.
4. Remove the driveshaft bolts and retainers. Discard the driveshaft bolts.
5. Tape the U-joint bearing caps to prevent them from falling off the U-joint.
6. Swing the driveshaft away from the axle pinion yoke and secure out of the way.
7. Remove the three (3) axle support mounting bracket bolts from the axle housing.
8. Position suitable jack beneath axle housing.
NOTE
PLACE FOLDED SHOP TOWELS OR SUITABLE SOFT MATERIAL OVER TORSION BARS TO
PROTECT THE HALFSHAFT BOOTS AND CLAMPS FROM DAMAGE.
9. Remove the two (2) bolts and nuts from the front axle support bushings. Discard the nuts.
10. Carefully lower and position the axle housing until it is resting on the torsion bars.
11. Disconnect the vent hose from the axle housing.
12. Position a drain pan under the axle housing cover. Rotate the axle housing slightly to allow
easy access to the axle cover bolts. Remove the axle housing cover and discard.
13. Clean the axle housing cover mounting surface.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 >
Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 1103
14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing
surface.
15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the
cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m).
16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the
kit (Figure 1).
17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit.
18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque
the bolts to 49 lb-ft (66 N.m).
19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106
N.m).
20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m).
21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90
Premium Rear Axle Lubricant. Install fill plug.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050620A 1995-2001 Explorer 1.5 Hrs.
1997-2001 Mountaineer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport
Trac: Install A Revised Axle Cover Kit
DEALER CODING
CONDITION
BASIC PART NO. CODE
4022 D1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 >
Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 1104
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 >
Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 1110
14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing
surface.
15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the
cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m).
16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the
kit (Figure 1).
17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit.
18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque
the bolts to 49 lb-ft (66 N.m).
19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106
N.m).
20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m).
21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90
Premium Rear Axle Lubricant. Install fill plug.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050620A 1995-2001 Explorer 1.5 Hrs.
1997-2001 Mountaineer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport
Trac: Install A Revised Axle Cover Kit
DEALER CODING
CONDITION
BASIC PART NO. CODE
4022 D1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 05-6-20 > Apr > 05 >
Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 1111
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Electronic Climate Control Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Electronic Climate Control Module > Page 1114
Control Module HVAC: Locations Blower Motor Speed Control
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Locations > Electronic Climate Control Module > Page 1115
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Electronic Climate Control Module
Control Module HVAC: Diagrams Electronic Climate Control Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Electronic Climate Control Module > Page 1118
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component
Information > Diagrams > Page 1119
Control Module HVAC: Description and Operation
The blower speed control is located on the evaporator housing in the engine compartment.
- The function of the blower motor speed control is to convert low power signals from the electronic
automatic temperature control module to a high current, variable ground feed for the blower motor.
- The blower motor speed is infinitely variable and is controlled by the electronic automatic
temperature control module software.
- A delay function provides a gradual increase or decrease in blower motor speed under all
conditions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Audible Warning Device Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1126
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1127
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1128
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1129
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1130
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1131
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1132
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1133
Audible Warning Device Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1134
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1135
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1136
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1137
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1138
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1139
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Page 1140
Audible Warning Device Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Page 1141
Audible Warning Device Control Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device
Control Module > Component Information > Diagrams > Page 1142
Audible Warning Device Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module >
Component Information > Description and Operation
Fuel Gauge Module: Description and Operation
NOTE:
- The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge
and instrument cluster gauge amplifier are calibrated together.
- If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication
may result. The ignition key must be placed in the OFF position during or after refueling for
accurate fuel gauge indication.
The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge
displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also
supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine
coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board
located in a pocket on the back of the instrument cluster. The electrical connections are made with
a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and
the instrument cluster gauge amplifier must be replaced as a unit.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module >
Component Information > Description and Operation > Page 1146
Fuel Gauge Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Fuel Gauge Module >
Component Information > Description and Operation > Page 1147
Fuel Gauge Module: Service and Repair
Service and Repair
The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and
must be replaced as a set.
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Locations > Page 1151
Instrument Panel Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Locations > Page 1152
Instrument Panel Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Instrument Panel Control
Module > Component Information > Locations > Page 1153
Instrument Panel Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Locations
Panel Illumination Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Locations > Page 1157
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Locations > Page 1158
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Locations > Page 1159
Panel Illumination Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Locations > Page 1160
Panel Illumination Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Panel Illumination Control
Module > Component Information > Locations > Page 1161
Panel Illumination Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations
Battery Discharge Protection Relay: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1166
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1167
Battery Discharge Protection Relay: Description and Operation
The following components are under the control of the battery saver relay:
^ Delayed accessory relay.
^ Overhead interior lamp with map lamps.
^ Overhead interior lamp switch.
^ Interior lamp relay coil.
The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake
mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode.
The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have
passed since the last active input. At that time, the relay will be deactivated and power to the above
circuits will terminate.
Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower
power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will
monitor only select inputs.
Logical characteristics of the GEM battery saver mode are as follows:
Feature Input: ^
Sleep/awake mode status.
Feature Output: ^
Battery saver relay control (open circuit in sleep mode, grounded when awake).
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1168
Battery Discharge Protection Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 1169
Battery Discharge Protection Relay: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications
Daytime Running Lamp Control Unit: Specifications
Daytime Running Lamps Control Module Bolts 3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 1173
Daytime Running Lamp Control Unit: Locations
Left front corner of engine.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 1174
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 1175
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the daytime running lamps (DRL) control module.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the DRL control module.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Locations > Page 1179
Exterior Lighting Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Locations > Page 1180
Exterior Lighting Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Locations > Page 1181
Exterior Lighting Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 1185
Fog/Driving Lamp Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay >
Component Information > Locations > Page 1189
Headlamp Dimmer Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 1193
Headlamp Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If
resistance is 5 ohms or less between terminal 2 and any
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations > Page 1194
other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two
jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73
Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not
indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal
2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage
is not indicated, replace the relay.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Part (1 Of 2)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1198
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1199
Horn Relay: Testing and Inspection
Terminals
Component Testing Procedure
Schematic
Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay
terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the
volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the
relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the
jumper wire to a known good
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 1200
ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1206
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1207
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1208
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1209
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1210
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1211
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Component Information > Diagrams > Diagram Information and Instructions > Page 1212
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1213
Interior Lighting Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1214
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1215
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1216
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1217
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1218
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 1219
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Page 1220
Interior Lighting Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Page 1221
Interior Lighting Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Page 1222
Interior Lighting Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations > Page 1226
Interior Lighting Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
Relay Module
Parking Lamp Relay is located in the relay module. Relay module is located behind center of I/P.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Page 1230
Parking Lamp Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Micro ISO Relay
> Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Mini ISO Relay >
Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
Power Distribution Relay: Locations
Trailer Tow Park Lamp Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 1244
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 1245
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 1246
Power Distribution Relay: Testing and Inspection
Trailer Tow Park Lamp Relay Test
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1251
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1252
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1253
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1254
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1255
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1256
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1257
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1258
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1259
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1260
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 1261
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Relay Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Relay Module > Page 1264
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Relay Module > Page 1265
Relay Box: Diagrams Auxiliary Relay Box #2
2 Door W/o Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Relay Module > Page 1266
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Relay Module > Page 1267
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1270
Fuse 1 - 18
Fuse 19 - 36
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1271
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1272
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1273
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1274
Fuse 32 - 36
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1275
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1276
Fuses
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1277
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1278
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1279
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
1280
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures
Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 1287
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 1288
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 1289
Powertrain Control Module: Specifications
PCM Connector 5 - 7 Nm
Powertrain Control Module Connector Bolt 7 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 1290
Powertrain Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 1291
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 1292
Powertrain Control Module: Diagrams
Part (1 Of 3)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 1293
Part (2 Of 3)
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 1294
Part (3 Of 3)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Description and Operation > General Description and Operation
Powertrain Control Module: Description and Operation General Description and Operation
The PCM performs the following functions:
^ accepts input from various engine sensors to compute the required fuel flow rate necessary to
maintain a prescribed air/fuel ratio throughout the entire engine operational range.
^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel.
^ determines and compensates for the age of the vehicle and its uniqueness, also automatically
senses and compensates for changes in altitude.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Description and Operation > General Description and Operation > Page 1297
Powertrain Control Module: Description and Operation Standard Models (Non BI-Fuel)
POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO)
The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem
generates vehicle speed information for distribution to the vehicle's electrical/electronic modules
and subsystems that require vehicle speed data. This subsystem senses the transmission output
shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired
signal or as a multiplexed data message.
The key features of the PCM-VSO system are to:
^ Infer vehicle movement from the output shaft sensor signal
^ Convert transmission output shaft rotational information to vehicle speed information
^ Compensate for tire size and axle ratio with a programmed calibration variable
^ Utilize a transfer case sensor for four wheel drive applications
^ Distribute vehicle speed information as a multiplexed message and/or an analog signal
The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft
Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is
sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per
mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into
the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing
changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information
can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM,
or by Speed and Odometer SCP multiplexed data messages.
The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT.
Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for
speed and distance data are transmitted as separate SCP messages over the SCP multiplex link.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory
Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read
Only Memory
Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM
Description
Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an
Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the
vehicle strategy including calibration information specific to the vehicle and is capable of being
reprogrammed or reflashed repeatedly.
As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM as under Programming the VID Block for
a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block
not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can
also be tailored to accommodate various hardware changes made to the vehicle since production.
Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of
Acceptable Range. This is described under Making Changes to the VID Block and also under
Making Changes to the PCM Calibration. The VID block contains many items used by the strategy
for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane,
fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel
drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle
hardware and supported by the VID block will be displayed on the scan tool.
When changing items in the VID block, the strategy will place range limits on certain items such as
tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When
this limit is reached, the scan tool will display a message indicating the need to flash the PCM
again to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other
Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic
tool manufacturers users manual for details.
Programming the VID Block for a Replacement PCM
A new PCM will contain the latest strategy and calibration level for a particular vehicle. However,
the VID block will be blank and will need programming. There are two procedures available. The
first is an automatic data transfer from the old PCM to the new PCM and the second is manual data
entry into the new PCM.
Automatic data transfer will be performed if the old PCM is capable of communicating. This is done
by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The
stored data can now be downloaded to the new PCM after it has been replaced.
Manual data entry must be performed if the old module is damaged and is incapable of
communicating. Remove and replace the old PCM. You may be instructed to contact the "AS
BUILT" data center for the information needed to manually update the VID block with the scan tool.
Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M
technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed
World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or
"Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 1300
Powertrain Control Module: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Powertrain Control Module (PCM) electrical connector.
3. Remove the nuts and the PCM cover.
4. Remove the PCM.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Powertrain Control Module Power Relay: Locations
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1304
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1305
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation
Air Injection Pump Relay: Description and Operation
SOLID STATE RELAY
Solid State Relay
The solid state relay (Figure 124) switches the high current required for operation of the electric
AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1314
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 1315
Fuel Pump Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Powertrain Control Module Power Relay: Locations
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1319
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 1320
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications
Air Bag Control Module: Specifications
Restraint Control Module Bracket 12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 1325
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 1326
Air Bag Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 1327
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 1328
Air Bag Control Module: Description and Operation
The Restraints Control Module (RCM) carries out the following functions:
^ signals the inflators to deploy the air bags in the event of a deployable crash.
^ monitors the air bag Supplemental Restraint System (SRS) for faults.
^ illuminates the air bag indicator if a fault is detected.
^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic
Trouble Codes (DTCs).
^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safety sensor is internal to the RCM and is not serviced separately.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it
will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and
historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the
system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The
chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag
indicator require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors determine that a deployment is required. The backup power supply will deplete its
stored energy approximately one minute after the battery ground cable is disconnected.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation
Air Bag Control Module: Service and Repair Removal and Installation
REMOVAL
WARNING:
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT
COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the right hand cowl side trim panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation > Page 1331
3. Disconnect the Restraints Control Module (RCM).
1 Slide the two RCM electrical connector locking clips down to disengage them.
2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical
connectors.
4. Remove the RCM with bracket.
1 Remove the three RCM bracket retaining bolts.
2 Remove the RCM with bracket.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation > Page 1332
1. Follow the removal procedure in reverse order.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: A repair is made by installing a new part only. If the part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation > Page 1333
Air Bag Control Module: Service and Repair Weld Nut Repair
"J" Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both procedures before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld
nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control
Module (RCM), Front External Crash and Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification.
Stripped Weld Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Missing Weld Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation > Page 1334
LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER
SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both procedures before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J"
Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts
must be installed as outlined in this procedure.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-5190).
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay >
Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation
Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation
Article No. 01-2-5
2/05/01
^ TRIM - SEAT BELT WARNING SYSTEM - "BELT
^ MINDER" FUNCTION - OPERATION AND SERVICE
^ TIPS
^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND
^ SERVICE TIPS
FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION,
F-150, RANGER, WINDSTAR 2001 EXPLORER
LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR
MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER
ISSUE
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning
function. This feature provides additional reminders to the driver that the driver's safety belt is
unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the
instrument cluster.
ACTION
Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by
performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt
Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following
Service Procedure.
SERVICE PROCEDURE
To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure.
1. Establish a session for the vehicle.
2. Select the "Toolbox" icon.
3. Select "Module Programming" and press the "Tick" mark.
4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark.
5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark.
6. WDS will display "Configuration Complete", then press the "Tick" mark.
NOTE:
IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT
LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH
HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT
WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS
EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE
SAFETY BELT IS BUCKLED.
NOTE:
WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND
CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT
WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND
FOR 4-8 SECONDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Warning Relay >
Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 1339
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 104000, 204000, 206000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
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Component Information > Locations > Page 1344
Part (1 Of 2)
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Component Information > Locations > Page 1345
Part (2 Of 2)
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Component Information > Locations > Page 1346
Starter Relay: Service Precautions
WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE
THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE
PROTECTIVE CAPS ARE IN PLACE.
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Component Information > Locations > Page 1347
Starter Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Component Information > Locations > Page 1348
Starter Relay: Service and Repair
REMOVAL
WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE
THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE
PROTECTIVE CAPS ARE IN PLACE.
1. Disconnect the battery ground cable.
2. Disconnect the starter motor solenoid relay switch wiring.
1 Remove the protective cover.
2 Disconnect the push-on electrical connector.
3 Remove the nuts.
4 Remove the cable.
3. Remove the starter motor solenoid relay switch.
1 Remove the engine sensor/generator wires.
2 Remove the bolts and ground wire.
3 Remove the starter motor solenoid relay switch.
INSTALLATION
1. Follow the removal procedure in reverse order.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Compressor/Pump Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Specifications
Suspension Control Module: Specifications
Air Suspension Control Module Mounting Screws 18 - 27 in.lb
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Suspension Control Module: Diagrams
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Suspension Control Module: Service and Repair
Removal
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Note: Ride heights must be reset for the air suspension module whenever the air suspension
module is replaced.
Disconnect the battery negative ground cable.
2. Remove the center instrument panel finish panel.
1 Remove the center instrument panel finish panel screws.
2 Disconnect the electrical connectors and remove the center panel finish panel.
3. Remove the air suspension control module.
1 Remove the air suspension control module screws.
2 Slide the air suspension control module down and out of the support bracket.
4. Disconnect the air suspension control module electrical connectors and remove the air
suspension control module.
Installation
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1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
Note: When installing a new air suspension control module, ride height adjustment must be
performed. Ride Height Adjustments
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- A/T > Control Module, A/T > Component Information > Service and Repair
Control Module: Service and Repair
Removal
1. Remove the transmission control switch (TCS).
1. Remove the TCS cover. 2. Remove the TCS.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions
Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1373
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1375
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1376
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1377
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1378
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1380
Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1385
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1386
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information and
Instructions > Page 1387
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- Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 1388
Control Module: Description and Operation
The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between
three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any
speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake
depressed and the transmission must be in NEUTRAL.
The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect
the speed of the front and rear driveshafts. This input is used by the generic electronic module
(GEM) primarily to control A4WD operation.
The throttle position output signal is provided to the GEM from the powertrain control module
(PCM). This signal is used by the GEM in controlling the A4WD clutch.
The shift motor sense plate an integral part of the electric shift motor informs the GEM to the
position of the transfer case.
The digital TR sensors are located on the LH side of the transmission; these sensors inform the
GEM when the transmission is in the neutral position.
The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam
which moves the mode fork and range fork within the transfer case between the HIGH range
(A4WD 4HIGH) and LOW range positions.
The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts
the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes.
The solid state clutch relay is used to activate the A4WD clutch within the transfer case.
System Function
Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM
varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under
cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of
time the clutch is turned on) which allows for the slight difference between the front and rear
driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the
following conditions the GEM will increase the duty cycle in order to prevent or control slip:
^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position).
Feature inputs:
^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch
(manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^
Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate
position inputs A B C D.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential
when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4
shift motor relay outputs.
Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and
outputs needed by the GEM to execute a change between any of these modes. Feature inputs:
^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD
mode switch.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential
when relay is off).
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^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated).
When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h
(3 mph) the brake is applied and the transmission is in NEUTRAL.
Feature inputs:
^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^
Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage
when brake is depressed open circuit when not activated). ^ Digital transmission range sensor
(ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input
(manual transmission only).
Feature outputs:
^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit
when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is
on baftery potential when relay is off).
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Control Module: Service and Repair
AUTOMATIC FOUR WHEEL DRIVE (A4WD)
Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives
Throttle Position Information From the PCM Only.
Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage may result.
Depower the supplemental restraint system (SRS).
2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact
Disc
3. Remove the center instrument panel finish panel.
1. Remove the screws. 2. Remove the center instrument panel finish panel.
^ Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the
GEM/CTM.
1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy.
2. To install, reverse the removal procedure.
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions
Four Wheel Drive Selector Relay: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Instructions > Page 1396
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Instructions > Page 1397
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Instructions > Page 1398
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1399
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1400
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1401
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1402
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and Modules
- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1403
Four Wheel Drive Selector Relay: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1404
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1405
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1406
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1407
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1408
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- Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and
Instructions > Page 1409
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Instructions > Page 1410
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Heated Glass Element
Relay > Component Information > Locations
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Relay > Component Information > Locations > Page 1415
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Heated Glass Element Relay: Testing and Inspection
Component Testing Procedure
Terminals
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Schematic
Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals.
If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the
volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the
relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the
jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not
indicated, replace the relay.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Locations
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Module > Component Information > Diagrams > Diagram Information and Instructions
Power Window Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1423
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1424
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1425
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1426
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1427
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1429
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1430
Power Window Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1431
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1432
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1433
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1434
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1435
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1436
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Power Window Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
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Module > Component Information > Diagrams > Page 1438
Power Window Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
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Module > Component Information > Diagrams > Page 1439
Power Window Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
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Component Information > Locations
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Component Information > Locations > Page 1443
Power Window Relay: Description and Operation
LH Front Window Regulator Control Switch Inputs Table
The GEM controls manual down and OTD window movement with the OTD relay.
The relay is activated by applying ground directly to one side of the down window relay coil, and is
deactivated by removing the ground signal.
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Component Information > Locations > Page 1444
Power Window Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Locations
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Control Module > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1451
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1452
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1453
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1454
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1455
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1456
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1457
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1458
Windshield Washer Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1459
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1460
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1461
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1462
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1463
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1464
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Page 1465
Windshield Washer Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Page 1466
Windshield Washer Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Control Module > Component Information > Diagrams > Page 1467
Windshield Washer Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Locations > Front Washer Pump Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Locations > Front Washer Pump Relay > Page 1472
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Locations > Page 1473
Windshield Washer Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Micro ISO Relay
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Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer
Relay > Component Information > Locations > Page 1474
Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts
position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If
battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to
a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace
the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions
Wiper Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1480
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1481
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1482
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1483
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1484
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1485
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1486
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1487
Wiper Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1488
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1489
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1490
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1491
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1492
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 1493
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Page 1494
Wiper Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Page 1495
Wiper Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control
Module > Component Information > Diagrams > Page 1496
Wiper Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay
Wiper Relay: Locations Rear Wiper Up Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1501
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1502
Wiper Relay: Locations Rear Wiper Down Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1503
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1504
Wiper Relay: Locations Wiper High Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1505
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1506
Wiper Relay: Locations Wiper Low Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1507
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1508
Wiper Relay: Locations Wiper Park Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Rear Wiper Up Relay > Page 1509
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 1510
Wiper Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Micro ISO Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations > Page 1511
Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts
position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If
battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to
a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace
the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock
Cylinder
Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder
REMOVAL
1. Remove the driver door trim panel.
3. Remove the door disarm switch.
1 Remove the "E" clip.
2 Remove the lock rod actuator.
3 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The door disarm switch locator mark must be positioned towards the harness side of the
switch prior to installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock
Cylinder > Page 1518
Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder
REMOVAL
1. Remove the liftgate trim panel. 2. Remove the watershield.
3. Remove the liftgate lock cylinder disarm switch.
1 Remove the "E" clip.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side
of the switch prior to installation.
^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock
Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder
Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder
REMOVAL
1. Remove the driver door trim panel.
3. Remove the door disarm switch.
1 Remove the "E" clip.
2 Remove the lock rod actuator.
3 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The door disarm switch locator mark must be positioned towards the harness side of the
switch prior to installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock
Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page
1523
Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder
REMOVAL
1. Remove the liftgate trim panel. 2. Remove the watershield.
3. Remove the liftgate lock cylinder disarm switch.
1 Remove the "E" clip.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side
of the switch prior to installation.
^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist
Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings
Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings
TSB 05-4-18
03/07/05
FALSE PARKING AID WARNINGS
FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty
LINCOLN: 2000-2001 Navigator
MERCURY: 1999-2001 Mountaineer
This article supersedes TSB 04-26-2 to update the vehicle lines and model years.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE TIPS
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive.
The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters)
from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
BLOCKED/CONTAMINATED PROXIMITY SENSOR
SURFACE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist
Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1532
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water wash to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid
module parameter identification displays (PIDs) for distance information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking Assist
Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1533
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select the appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT:
^ Toolbox Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking
Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False
Warnings
TSB 05-4-18
03/07/05
FALSE PARKING AID WARNINGS
FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty
LINCOLN: 2000-2001 Navigator
MERCURY: 1999-2001 Mountaineer
This article supersedes TSB 04-26-2 to update the vehicle lines and model years.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE TIPS
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive.
The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters)
from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
BLOCKED/CONTAMINATED PROXIMITY SENSOR
SURFACE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking
Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1539
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water wash to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid
module parameter identification displays (PIDs) for distance information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking
Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 1540
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select the appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT:
^ Toolbox Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1541
Parking Assist Distance Sensor: Specifications
Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm
Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor
160 cm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1542
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 1543
Parking Assist Distance Sensor: Service and Repair
REMOVAL
1. Remove the rear bumper.
2. Remove the parking aid sensor.
1 Disconnect the electrical connector.
2 Release the tabs.
3 Remove the parking aid sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Switch > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Switch > Component Information > Diagrams > Page 1547
Parking Assist Switch: Service and Repair
REMOVAL
1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc.
2. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel.
^ Disconnect the electrical connector.
3. Remove the hood latch release handle.
1 Remove the screws.
2 Remove the hood latch release handle.
4. Remove the instrument panel lower steering column cover.
1 Remove the screws.
2 Remove the instrument panel lower steering column cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Parking
Assist Switch > Component Information > Diagrams > Page 1548
5. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the screws.
2 Remove the instrument panel steering column opening cover reinforcement.
6. If equipped, position the column gearshift lever aside.
7. Remove the instrument cluster finish panel.
1 Remove the screws.
2 Remove the instrument cluster finish panel. ^
Disconnect the electrical connector.
8. Remove the parking aid switch.
1 Remove the screws.
2 Remove the parking aid switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote
Switch, Audio - Stereo > Component Information > Service and Repair
Remote Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the steering wheel controls.
1 Carefully remove the steering wheel controls.
2 Disconnect the steering wheel controls.
NOTE: The steering wheel is leather wrapped and should be protected when removing the steering
wheel controls.
INSTALLATION
1. Install the steering wheel controls.
1 Connect the steering wheel controls.
2 Install the steering wheel controls.
2. Connect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page
1558
OASIS CODES: 201000, 201200
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Master Window/Door Lock Control Switch
4 Door
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 1563
Power Door Lock Switch: Diagrams Power Door Lock Switch
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Left Front
Power Door Lock Switch: Testing and Inspection Left Front
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Left Front > Page 1566
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Left Front > Page 1567
Power Door Lock Switch: Testing and Inspection Right Front
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Left Front > Page 1568
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1572
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1573
Power Mirror Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 1574
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Left
Power Seat Switch: Diagrams Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Diagrams > Left > Page 1579
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service Precautions > Technician Safety Information
Power Seat Switch: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service Precautions > Technician Safety Information > Page 1582
Power Seat Switch: Vehicle Damage Warnings
CAUTION:
- To prevent damage to the side shield, the clips must be depressed in order to release the side
shield from the cushion pan.
- Use care when disconnecting the seat cushion side shield from the seat cushion frame so the
tabs on the seat cushion side shield are not damaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Seat Memory Set Switch
Power Seat Switch: Testing and Inspection Seat Memory Set Switch
Remove the memory set switch. Measure the resistance between the indicated terminals while
pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the
calling Pinpoint Test.
To check the memory set switch LED, connect the positive meter lead to terminal 8 and the
negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads,
the meter should read OL.
If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling
Pinpoint Test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Testing and Inspection > Seat Memory Set Switch > Page 1585
Power Seat Switch: Testing and Inspection Seat Regulator Control Switch
Remove the seat regulator control switch. Measure the resistance between the indicated terminals
while pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the
calling Pinpoint Test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Sport Bucket
Power Seat Switch: Service and Repair Sport Bucket
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket,
3. Remove the lumbar support knob.
4. Remove the rear side shield screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Sport Bucket > Page 1588
5. Release the side shield clips.
CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release
the side shield from the cushion pan.
6. Unhook the side shield from the seat latch.
7. If equipped, disconnect the heated seat switch electrical connector.
8. Remove the side shield.
1 Disconnect the electrical connector.
2 Remove the side shield.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Sport Bucket > Page 1589
9. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For
additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional
information, refer to Air Bag Systems. 4. Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Sport Bucket > Page 1590
Power Seat Switch: Service and Repair Limited
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Sport Bucket > Page 1591
5. Remove the front seat cushion side shield screws.
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Disconnect the lumbar support control switch electrical connector.
8. Disconnect the lumbar support adjusting hoses from the adjusting switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Service and Repair > Sport Bucket > Page 1592
9. If equipped, disconnect the heated seat switch electrical connector.
10. Remove the front seat cushion side shield.
11. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Diagrams > Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Diagrams > Left > Page 1597
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Sport Bucket
Seat Heater Switch: Service and Repair Sport Bucket
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Remove the lumbar support knob.
4. Remove the rear side shield screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Sport Bucket > Page 1600
5. Release the side shield clips.
6. Disconnect the heated seat switch electrical connector.
7. Remove the heated seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Sport Bucket > Page 1601
Seat Heater Switch: Service and Repair Limited
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat Systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Sport Bucket > Page 1602
5. Remove the front seat cushion side shield screws.
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Disconnect the lumbar support control switch electrical connector.
8. Disconnect the lumbar support adjusting hoses from the adjusting switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Service and Repair > Sport Bucket > Page 1603
9. Disconnect the heated seat switch electrical connector.
10. Remove the front seat cushion side shield.
11. Remove the heated seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch
> Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 1613
Trunk / Liftgate Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 1614
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Locations > Page 1619
Acceleration/Deceleration Sensor: Service and Repair
Removal
1. Raise and support the vehicle.
2. Remove the nuts.
3. Unclip the fuel filter from the vehicle frame.
4. Remove the G-switch.
1 Disconnect the G-switch electrical connector.
2 Remove the G-switch.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Locations > Page 1620
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Locations > Page 1624
Brake Fluid Level Sensor/Switch: Description and Operation
The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder
reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the
brake master cylinder reservoir.
When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the
floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate.
Loss of brake fluid will cause this system to activate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Pressure Sensor/Switch > Component Information > Specifications
Brake Fluid Pressure Sensor/Switch: Specifications
Brake pressure switch 11-14 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake
Release Switch > Component Information > Specifications
Parking Brake Release Switch: Specifications
Parking brake remote release to instrument panel
......................................................................................................................... 2.1-2.9 Nm (19-25 ft.
lbs)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications
Wheel Speed Sensor: Specifications
Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb
Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb
Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb
Rear anti-lock brake sensor bolt 20 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Left Front
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Left Front > Page 1639
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front
Wheel Speed Sensor: Service and Repair Sensor, Front
Removal
1. Remove the rotor shield.
2. Disconnect the front anti-lock brake sensor electrical connector.
3. Unclip the front anti-lock brake sensor wire from the vehicle frame.
4. Remove the bolt.
5. Remove the front anti-lock brake sensor.
1 Remove the bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 1642
2 Remove the front anti-lock brake sensor.
Installation
1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High
Temperature 4x4 Front Axle and Wheel Bearing
Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 1643
Wheel Speed Sensor: Service and Repair Sensor, Rear
Removal
1. Raise and support vehicle.
2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor
before removal.
Remove the rear anti-lock brake sensor. 1
Disconnect the rear anti-lock brake sensor electrical connector.
2 Remove the bolt.
3 Remove the rear anti-lock brake sensor.
Installation
1. NOTE: Thoroughly clean the mounting surface.
NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 15 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1649
Coolant Temperature Sensor/Switch (For Computer): Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1650
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 1651
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Remove the thermostat and housing. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the Engine Coolant Temperature (ECT) sensor.
1 Disconnect the connector.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature Sensor > Page 1656
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Engine coolant temperature (ECT) sensor 89 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications > Page 1660
Temperature Sensor (Gauge): Description and Operation
When the engine temperature is low, the resistance of the water temperature indicator sender unit
is high, thus restricting the flow of current through the gauge and moving the pointer only a short
distance. As the temperature of the coolant increases, the resistance decreases, allowing more
current to flow through the gauge and results in a corresponding movement of the pointer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 >
Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch
Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1674
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1675
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1676
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1677
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1678
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1679
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1680
Attachment III - Technical Information
Table of Contents
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1681
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1682
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1683
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1684
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1685
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1686
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1687
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1688
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1689
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1690
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1691
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1692
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1693
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1694
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1695
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1696
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1697
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1698
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08
> Recall - Cruise Control Deactivation Switch Inspection > Page 1699
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 >
Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 >
Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 1704
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control)
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch
Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control
Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
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05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1714
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1715
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1716
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1717
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1718
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1719
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05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1720
Attachment III - Technical Information
Table of Contents
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SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
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The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
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05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1723
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
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05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1724
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
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2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
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9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1738
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 1739
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> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control
Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
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CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
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> Component Information > Technical Service Bulletins > Page 1745
Brake Switch (Cruise Control): Specifications
Deactivator Switch 15-20 Nm
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> Component Information > Service Precautions > Technician Safety Information
Brake Switch (Cruise Control): Technician Safety Information
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.
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> Component Information > Service Precautions > Technician Safety Information > Page 1748
Brake Switch (Cruise Control): Vehicle Damage Warnings
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
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> Component Information > Service Precautions > Page 1749
Brake Switch (Cruise Control): Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the deactivator switch electrical connector.
3. Remove the deactivator switch.
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE
^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles)
or more to relearn the strategy.
^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes.
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> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating
Technical Service Bulletin # 09S09 Date: 091013
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> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1758
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on October 13, 2009.
NOTE:
This recall pertains to certain vehicles that have a factory installed speed control deactivation
switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering
wheel identical to the factory-installed system. The Ford accessory kit does not use a master
cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this
recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in
OASIS under 09509, the vehicle is not involved in the program.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and
addresses will be available by December 18, 2009.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
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> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1759
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the
vehicle.
^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair
was performed prior to the date indicated in the reimbursement plan, which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or, at their option,
directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan.
Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control
deactivation switch.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 09S09 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS
adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on
same repair line as repair.)
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $6.30
^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness
connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair
line as repair.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1760
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $0.50
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1761
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this safety recall is 50409.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Affected speed control deactivation switches and related damage parts are subject to random
selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS
(Parts Entry and Return System) register for part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1762
TABLE OF CONTENTS
OVERVIEW
This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS)
harness connector for the presence of brake fluid contamination. If no brake fluid is present, install
the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the
speed control servo harness connector for heat damage. See Flow Chart # 2.
In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the
Anti-lock Brake System (ABS) connectors. See Flow Chart # 2.
If a related damage condition is found that you believe to be caused by a leaking SCDS, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
REPAIR FLOW CHARTS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1763
Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003
Windstar vehicles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1764
Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles.
SCDS Identification
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1765
The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised
SCDS are illustrated (See Figure 1).
Note that the revised SCDS has a different electrical connector An adapter jumper harness (which
is included in the parts kit) is required when replacing the old SCDS with the revised SCDS
SCDS Location
In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993
E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve
on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located
on the junction block or brake proportioning valve on the left frame rail below the master cylinder
To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53
Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
SCDS INSPECTION PROCEDURE
NOTE:
For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If
unable to locate a SCDS after checking on all the brake lines, no further action is required, release
the vehicle
NOTE:
On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain
access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle
to gain access to the SCDS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1766
1. Disconnect the harness connector from the SCDS (See Figure 2)
2. Inspect the harness connector for the presence of brake fluid.
^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness
(UFJH).
^ If there is evidence of brake fluid on the connector, replace SCDS.
UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION
1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness.
2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are
positioned vertically with the fuse holder cap facing upward
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1767
Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse
holder orientation (See Figure 3).
3. No further action is required release the vehicle.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US),
CPM-1-C (Canada), to the fluid port at the
threaded end of the new SCDS (See Figure 4).
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed
3. Remove the old SCDS.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed
from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft).
5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake
fluid reservoir cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1768
6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II
(XG-15-A) (See Figure 5).
7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the adapter jumper
harness to a nearby component such as the speed control cable or another wire harness.
^ If the vehicle has a speed control servo, proceed with speed control servo inspection.
^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS
inspection.
^ If none of the above apply, no further action is required, release the vehicle.
SPEED CONTROL SERVO INSPECTION
1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage
(See Figure 6)
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector) proceed to step 2 for further instructions.
^ If heat damage is found proceed as follows:
- 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center
for further instructions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1769
- All other vehicles call the Special Service Support Center for further instructions.
2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from
the speed control servo harness electrical
connector and the servo module. Do not use any type of solvent to clean the connectors.
3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire
width and length of the servo vehicle harness
connector (See Figure 7).
NOTICE:
Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT
apply the grease directly to the connector of the servo module.
4. Reconnect the harness to the servo module.
5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is
required, release the vehicle.
ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION
NOTE:
This inspection applies to 1999 through 2003 Windstar vehicles only.
1. Lift vehicle and remove ABS cover.
2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of
brake fluid.
3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness
connector and module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1770
4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure
8).
5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module
connector call the Special Service Support Center for
further instructions.
6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS
module.
7. Is the speed control servo heat damaged?
^ If the speed control servo is heat damaged call the Special Service Support Center for further
instructions.
^ If the speed control servo is not heat damaged no further action is required release the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1771
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 1772
Owner Letter
Owner Letter not available at this time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating
Technical Service Bulletin # 09S09 Date: 091013
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1778
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on October 13, 2009.
NOTE:
This recall pertains to certain vehicles that have a factory installed speed control deactivation
switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering
wheel identical to the factory-installed system. The Ford accessory kit does not use a master
cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this
recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in
OASIS under 09509, the vehicle is not involved in the program.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and
addresses will be available by December 18, 2009.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1779
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the
vehicle.
^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair
was performed prior to the date indicated in the reimbursement plan, which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or, at their option,
directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan.
Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control
deactivation switch.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 09S09 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS
adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on
same repair line as repair.)
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $6.30
^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness
connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair
line as repair.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1780
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $0.50
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1781
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this safety recall is 50409.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Affected speed control deactivation switches and related damage parts are subject to random
selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS
(Parts Entry and Return System) register for part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1782
TABLE OF CONTENTS
OVERVIEW
This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS)
harness connector for the presence of brake fluid contamination. If no brake fluid is present, install
the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the
speed control servo harness connector for heat damage. See Flow Chart # 2.
In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the
Anti-lock Brake System (ABS) connectors. See Flow Chart # 2.
If a related damage condition is found that you believe to be caused by a leaking SCDS, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
REPAIR FLOW CHARTS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1783
Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003
Windstar vehicles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1784
Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles.
SCDS Identification
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1785
The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised
SCDS are illustrated (See Figure 1).
Note that the revised SCDS has a different electrical connector An adapter jumper harness (which
is included in the parts kit) is required when replacing the old SCDS with the revised SCDS
SCDS Location
In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993
E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve
on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located
on the junction block or brake proportioning valve on the left frame rail below the master cylinder
To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53
Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
SCDS INSPECTION PROCEDURE
NOTE:
For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If
unable to locate a SCDS after checking on all the brake lines, no further action is required, release
the vehicle
NOTE:
On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain
access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle
to gain access to the SCDS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1786
1. Disconnect the harness connector from the SCDS (See Figure 2)
2. Inspect the harness connector for the presence of brake fluid.
^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness
(UFJH).
^ If there is evidence of brake fluid on the connector, replace SCDS.
UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION
1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness.
2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are
positioned vertically with the fuse holder cap facing upward
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1787
Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse
holder orientation (See Figure 3).
3. No further action is required release the vehicle.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US),
CPM-1-C (Canada), to the fluid port at the
threaded end of the new SCDS (See Figure 4).
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed
3. Remove the old SCDS.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed
from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft).
5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake
fluid reservoir cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1788
6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II
(XG-15-A) (See Figure 5).
7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the adapter jumper
harness to a nearby component such as the speed control cable or another wire harness.
^ If the vehicle has a speed control servo, proceed with speed control servo inspection.
^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS
inspection.
^ If none of the above apply, no further action is required, release the vehicle.
SPEED CONTROL SERVO INSPECTION
1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage
(See Figure 6)
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector) proceed to step 2 for further instructions.
^ If heat damage is found proceed as follows:
- 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center
for further instructions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1789
- All other vehicles call the Special Service Support Center for further instructions.
2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from
the speed control servo harness electrical
connector and the servo module. Do not use any type of solvent to clean the connectors.
3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire
width and length of the servo vehicle harness
connector (See Figure 7).
NOTICE:
Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT
apply the grease directly to the connector of the servo module.
4. Reconnect the harness to the servo module.
5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is
required, release the vehicle.
ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION
NOTE:
This inspection applies to 1999 through 2003 Windstar vehicles only.
1. Lift vehicle and remove ABS cover.
2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of
brake fluid.
3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness
connector and module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1790
4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure
8).
5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module
connector call the Special Service Support Center for
further instructions.
6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS
module.
7. Is the speed control servo heat damaged?
^ If the speed control servo is heat damaged call the Special Service Support Center for further
instructions.
^ If the speed control servo is not heat damaged no further action is required release the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1791
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control
> Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 1792
Owner Letter
Owner Letter not available at this time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09
> Recall 09V399000: Cruise Control Deactivation Switch
Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: >
NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch
Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control
Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > Page 1806
Cruise Control Switch: Specifications
Speed Control Actuator Switch Screws 6.5-7.5 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Technical Service Bulletins > Page 1807
Cruise Control Switch: Service Precautions
CAUTION: When separating the speed control actuator switch from the steering wheel, it is
necessary to take precautions not to damage the steering wheel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair > Without Remote Audio
Cruise Control Switch: Service and Repair Without Remote Audio
REMOVAL
1. Remove the driver side air bag module. Refer to Air Bag Systems.
2. Remove the speed control actuator switches.
1 Remove the screws.
2 Disconnect the electrical connector then remove the speed control actuator switches.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10
miles) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Service and Repair > Without Remote Audio > Page 1810
Cruise Control Switch: Service and Repair With Remote Audio
REMOVAL
1. Disconnect the battery ground cable.
2. Separate the speed control actuator switch out of the steering wheel.
CAUTION: When separating the speed control actuator switch from the steering wheel, it is
necessary to take precautions not to damage the steering wheel.
3. Remove the speed control actuator switch.
1 Disconnect the speed control actuator switch electrical connector.
2 Remove the speed control actuator switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn its strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Specifications
Oil Pressure Sender: Specifications
Oil pressure sensor 9-11 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Specifications > Page 1815
Oil Pressure Sender: Description and Operation
The oil pressure switch is installed in the engine block and consists of a diaphragm and contact
points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil
pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Specifications > Page 1816
Oil Pressure Sender: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Additional information may also be found at Engine; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Specifications > Page 1817
Oil Pressure Sender: Service and Repair
Removal and Installation
1. Discard the battery ground cable.
2. Disconnect the oil pressure sensor electrical connector and remove the sensor.
3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or
Wsk-M2G350-A2.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch > Component
Information > Service and Repair
Air Conditioning Switch: Service and Repair
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1825
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch
HVAC > Component Information > Locations > Page 1826
Ambient Temperature Sensor / Switch HVAC: Description and Operation
The A/C ambient air temperature sensor and bracket:
- is located in front of the A/C condenser core near the center of the vehicle.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the electronic automatic temperature control assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Cabin Temperature Sensor / Switch >
Component Information > Locations > Page 1833
Cabin Temperature Sensor / Switch: Description and Operation
The in-car temperature sensor operates in the following manner:
- A thermistor in the in-car temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the plenum
assembly and the in-car temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the plenum assembly air
stream to create a suction in the in-car temperature sensor.
- The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Specifications
Refrigerant Pressure Sensor / Switch: Specifications
A/C Cycling Switch 324 kPa
Close Minimum
A/C Cycling Switch 152 kPa
Open Minimum
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Specifications > Page 1837
Refrigerant Pressure Sensor / Switch: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Specifications > Page 1838
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Specifications > Page 1839
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Specifications > Page 1840
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
A/C Cycling Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction
accumulator/drier.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction pressure inside the suction accumulator/drier to control the operation of
the A/C cycling switch.
- The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi).
- The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi).
- When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the
wide open throttle A/C cutoff relay.
- When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of airflow.
- It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 1843
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch
PCM Inputs
AIR CONDITIONING CYCLING SWITCH
The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or
ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will
turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling
switch, refer to Heating and Air Conditioning.
The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when
the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch
and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are
closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle
specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See:
Powertrain Management/Description and Operation/PCM Outputs
NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C
is requested. This information is received by the PCM through the BUS + and BUS - Standard
Corporate Protocol (SCP) communication.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch,
HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 1844
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure
Switch
Typical Air Conditioning Pressure Sensor
The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure
side of the A/C manifold and tube.
- A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch
contacts open, disengaging the A/C compressor.
- When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow
operation of the A/C compressor.
- It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations
Solar Sensor: Locations
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 1848
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 1849
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Solar Sensor, HVAC > Component
Information > Locations > Page 1850
Solar Sensor: Description and Operation
The A/C sunload sensor:
- is located on the top side of the instrument panel.
- contains a photovoltaic diode that is sensitive to light.
- has some unspecified resistance across the terminals depending upon the amount of light
reaching the photovoltaic diode; therefore the only test that can be performed is for an internal
short circuit.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Service and Repair
Dimmer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch >
Component Information > Service and Repair > Page 1855
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component
Information > Locations > Page 1859
Door Switch: Service and Repair
REMOVAL
1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door
Latch.
3. Remove the door opening warning lamp switch.
1 Lift the locking tab.
2 Rotate the door opening warning lamp switch counterclockwise.
3 Remove the door opening warning lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Testing and Inspection
Fuel Gauge Sender: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Testing and Inspection > Page 1863
Fuel Gauge Sender: Service and Repair
Service and Repair
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch >
Component Information > Service and Repair
Key Reminder Switch: Service and Repair
For further information regarding the service of this component and the system that it is part of,
please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning
Devices.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations > Page 1870
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 1875
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Specifications
Backup Lamp Switch: Specifications
Backup Lamp Switch 25-35 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Specifications > Page 1879
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Specifications > Page 1880
Backup Lamp Switch: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Specifications > Page 1881
Backup Lamp Switch: Service and Repair
REMOVAL
1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the
backup lamp switch electrical connector.
3. Remove the backup lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position
Switch <--> [Brake Light Switch] > Component Information > Locations
Exterior Lighting System Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position
Switch <--> [Brake Light Switch] > Component Information > Locations > Page 1885
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Pedal Position
Switch <--> [Brake Light Switch] > Component Information > Locations > Page 1886
Brake Pedal Position Switch: Description and Operation
BRAKE PEDAL POSITION SWITCH
Typical Brake Pedal Position Switch
The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the
transmission torque converter clutch and on some applications as an input to the idle speed control
for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery
positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch
signal is broadcast over the SCP link via another module to be received by the PCM.
On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all
stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor
in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has
failed.
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Switch <--> [Brake Light Switch] > Component Information > Locations > Page 1887
Brake Pedal Position Switch: Service and Repair
REMOVAL
1. Disconnect the brake pedal position (BPP) switch connector.
2. Remove the BPP switch
1 Remove the self-locking pin.
2 Remove the spacer.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Testing and Inspection
Combination Switch: Testing and Inspection
For further information regarding this component please refer to Turn Signal Switch; Testing and
Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Testing and Inspection > Page 1891
Combination Switch: Service and Repair
For further information regarding this component please refer to Turn Signal Switch; Service and
Repair.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch >
Component Information > Locations > Page 1895
Door Switch: Service and Repair
REMOVAL
1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door
Latch.
3. Remove the door opening warning lamp switch.
1 Lift the locking tab.
2 Rotate the door opening warning lamp switch counterclockwise.
3 Remove the door opening warning lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch
> Component Information > Specifications
Fog/Driving Lamp Switch: Specifications
Fog Lamp Switch Mounting Bezel Screws 2-3 Nm
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> Component Information > Specifications > Page 1899
Exterior Lighting System Components
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> Component Information > Specifications > Page 1900
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch
> Component Information > Specifications > Page 1901
Fog/Driving Lamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel.
3 Disconnect the electrical connectors.
3. Remove the fog lamp switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the fog lamp switch.
INSTALLATION
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> Component Information > Specifications > Page 1902
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams
Hazard Warning Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 1906
Hazard Warning Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
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Component Information > Diagrams > Page 1907
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 1908
Schematic
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Component Information > Diagrams > Page 1909
Schematic
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams
Headlamp Dimmer Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 1913
Headlamp Dimmer Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 1914
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 1915
Schematic
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Diagrams > Page 1916
Schematic
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Specifications
Headlamp Switch: Specifications
Head Lamp Switch Screws 2-3 Nm
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Component Information > Specifications > Page 1920
Exterior Lighting System Components
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Component Information > Diagrams > Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Component Information > Diagrams > Diagram Information and Instructions > Page 1923
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Component Information > Diagrams > Diagram Information and Instructions > Page 1924
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1925
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1926
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Component Information > Diagrams > Diagram Information and Instructions > Page 1927
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Component Information > Diagrams > Diagram Information and Instructions > Page 1928
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Component Information > Diagrams > Diagram Information and Instructions > Page 1929
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1930
Headlamp Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Component Information > Diagrams > Diagram Information and Instructions > Page 1931
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Component Information > Diagrams > Diagram Information and Instructions > Page 1932
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Component Information > Diagrams > Diagram Information and Instructions > Page 1933
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Component Information > Diagrams > Diagram Information and Instructions > Page 1934
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Component Information > Diagrams > Diagram Information and Instructions > Page 1935
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Component Information > Diagrams > Diagram Information and Instructions > Page 1936
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 1937
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 1938
Headlamp Switch: Testing and Inspection
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 1939
Schematic
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 1940
Headlamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening
cover reinforcement; refer to Dashboard.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the instrument panel finish panel.
4. Remove the instrument cluster finish panel.
1 Remove the screws.
2 Remove the cluster instrument panel finish panel.
5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob.
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Component Information > Diagrams > Page 1941
6. Remove the headlamp switch.
1 Remove the screws.
2 Remove the headlamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Description and Operation
Horn Switch: Description and Operation
The horn blow switches are underneath the driver side air bag module in the steering wheel. The
switches are powered through the air bag sliding contact and ground through the steering column.
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Component Information > Description and Operation > Page 1945
Horn Switch: Service and Repair
REMOVAL
1. Remove the driver side air bag; refer to Air Bag Systems.
2. Remove the switches.
1 Disconnect the horn wire (BK) from the switches.
2 Remove the attaching bolts from the switches and remove the switches.
INSTALLATION
1. To install, reverse the removal procedure.
^ Prove out the air bag system; refer to Air Bag Systems.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Component Information > Service and Repair
Interior Light Switch: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Remove the interior lamp switch.
1 Disconnect the interior lamp switch electrical connector.
2 Remove the interior lamp switch. ^
Push inward; rotate counterclockwise.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams
Turn Signal Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 1952
Turn Signal Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
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Component Information > Diagrams > Page 1953
Component Testing Procedure
Terminals
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Component Information > Diagrams > Page 1954
Schematic
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Component Information > Diagrams > Page 1955
Schematic
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Component Information > Diagrams > Page 1956
Turn Signal Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
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Component Information > Diagrams > Page 1957
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch
> Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch
> Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 1962
OASIS CODES: 201000, 201200
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and
Operation
Absolute Pressure Sensor: Description and Operation
THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR
Thermal Manifold Absolute Pressure (TMAP) Sensor
The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold
Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is
currently not being used. The MAP part of the sensor measures intake manifold air absolute
pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air
Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP)
sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced
into the intake manifold.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Specifications
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Nuts And Bolts 10 Nm
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Specifications > Page 1971
Mass Air Flow Sensor: Locations
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Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Specifications > Page 1972
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Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Specifications > Page 1973
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
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> Specifications > Page 1974
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Loosen the air cleaner outlet tube clamp and position aside.
4. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor, Stud Bolt 19 Nm
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1978
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
1979
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
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1980
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the CMP sensor electrical connector.
2 Remove the CMP sensor stud bolt.
3 Remove the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 1984
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION SWITCH
Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches
The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch
pedal position and, in some manual transmission applications, both the clutch pedal engagement
position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference
Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP
signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed,
indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output
voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1
volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or
PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the
clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP
switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the
5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load
information in mass air flow and fuel calculations.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 15 Nm
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1988
Coolant Temperature Sensor/Switch (For Computer): Locations
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1989
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 1990
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Remove the thermostat and housing. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the Engine Coolant Temperature (ECT) sensor.
1 Disconnect the connector.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolts 10 Nm
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 1994
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and
Operation > Electronic Engine Controls
Crankshaft Position Sensor: Description and Operation Electronic Engine Controls
The CKP sensor:
^ sends the PCM a signal indicating crankshaft position.
^ is essential for calculating spark timing.
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and
Operation > Electronic Engine Controls > Page 1997
Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel)
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and
Operation > Page 1998
Crankshaft Position Sensor: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Crankshaft Position (CKP) sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor
has wear tabs that will wear off after several engine revolutions.
^ Be sure sensor wiring is routed away from the battery cable.
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Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
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Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature Sensor > Page 2003
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation
Fuel Level Sensor: Description and Operation
The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the
action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is
high, the resistance is high.
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Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page
2010
Fuel Tank Pressure Sensor: Service Precautions
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
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2011
Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure Sensor
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor
(Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles
equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank
pressure by forcing the system to purge.
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2012
Fuel Tank Pressure Sensor: Service and Repair
REMOVAL
1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction.
2. Remove the fuel tank pressure sensor.
1 Disconnect the electrical connector.
2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the
fuel tank.
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test the evaporative emission system. For additional information, refer to Evaporative
Emission System Leak Test System. See: Powertrain Management/Emission Control
Systems/Evaporative Emissions System/Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emissions repair verification drive cycle. For additional information,
refer to Evaporative Emission Repair Verification Drive Cycle. See: Powertrain
Management/Emission Control Systems/Evaporative Emissions System/Service and Repair
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Operation
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE SENSOR
Intake Air Temperature (IAT)
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals
The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type
(Figure 37), are thermistor devices in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
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Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel spark and MAF.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above.
However, one is located before the supercharger at the air cleaner for standard OBD II/cold
weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control border-line spark and to help determine intercooler
efficiency.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Bolt 25 Nm
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2020
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 2021
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Knock Sensor: Service and Repair
REMOVAL
1. Remove the lower in take manifold. For additional information, refer to Engine.
2. Remove the knock sensor.
1 Remove the bolt.
2 Remove the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 2027
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Heated Oxygen Sensor: Specifications
Heated Oxygen Sensor 41 Nm
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Locations > Oxygen Sensor Bank Locations
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Locations > Oxygen Sensor Bank Locations > Page 2045
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Diagrams > Diagram Information and Instructions
Heated Oxygen Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2051
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2052
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2053
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2054
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2055
Heated Oxygen Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2056
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2057
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2058
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2059
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2060
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2061
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 2062
Heated Oxygen Sensor: Connector Views
Ford does not provide connector views for this vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Page 2063
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor Monitor
The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S
sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream
HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean
to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper
output voltage. The following illustration shows that input is required from the Engine Coolant
Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air
Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel
System Monitor and Misfire Detection Monitor must also have completed successfully before the
HO2S Monitor is enabled.
1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel
ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich
of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor
evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper
function.
2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response
frequency are checked. Excessive voltage is
determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A
fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S
heater circuit fault is determined by turning the heater on and off and looking for a corresponding
change in the Output State Monitor (OSM) and by measuring the current going through the heater
circuit. The HO2S Monitor DTCs can be categorized as follows:
The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130,
P1131, P1132, P1150, P1151 and P1152.
The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153.
The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151
and P0156.
The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and
P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in
on-demand is DTC P1127.
The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129.
3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive
drive cycles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 2066
Heated Oxygen Sensor: Description and Operation PCM Inputs
HEATED OXYGEN SENSOR
Heated Oxygen Sensor (HO2S)
The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and
produces a variable voltage according to the amount of oxygen detected. A high concentration of
oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low
concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The
HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near
stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop
operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will
complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater
and heater control system are installed on some vehicles. The high power heater reaches closed
loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty
cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style
3.3 ohm heater.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Page 2067
Heated Oxygen Sensor: Service and Repair
EGO Sensor Wrench
SPECIAL SERVICE TOOL(S)
REMOVAL
NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and
Repair.
2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For
additional information, refer to Catalytic Converter.
4. Using the special tool, remove the HO2S.
NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or
equivalent to assist in removal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or
equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Page 2068
Syncro Positioning Tool
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 2077
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 2078
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 2079
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 2080
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 2081
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2087
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2088
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2089
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2090
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2091
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2096
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2097
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2098
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2104
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2105
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2106
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 2107
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR Bolts 8 - 10 Nm
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 2108
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 2109
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 2110
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 2111
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the differential pressure feedback EGR electrical connector.
3. Disconnect the differential pressure feedback EGR hoses.
4. Remove the bolts and the differential pressure feedback EGR.
INSTALLATION
1. Fit the differential pressure feedback EGR and loosely install the bolts.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 2112
2. Tighten the bolts.
3. Connect the differential pressure feedback EGR hoses.
4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery
ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2116
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > PCM Inputs > Page 2119
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 2120
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Remove the Throttle Position (TP) sensor.
1 Disconnect the TP sensor electrical connector.
2 Remove the sensor.
NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 2124
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 2125
Digital Transmission Range Sensor: Diagrams
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 2126
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
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Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 2127
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
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Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 2128
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor Bolt 98 - 115 in.lb
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2134
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Information and Instructions > Page 2135
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2136
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2137
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2138
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2139
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2140
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2141
Vehicle Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2142
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2143
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2144
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2145
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2146
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2147
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2148
Diagram 64-1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 2149
Vehicle Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
Typical Vehicle Speed Sensor (VSS)
The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that
generates a waveform with a frequency that is proportional to the speed of the vehicle. If the
vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As
the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM
uses the frequency signal generated by the VSS (and other inputs) to control such parameters as
fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch
scheduling.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2159
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2160
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2161
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2162
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 2163
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 2169
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 2170
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 2171
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 2172
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 2173
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2178
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2179
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 2180
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2186
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2187
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 2188
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 2189
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR Bolts 8 - 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 2190
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 2191
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 2192
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 2193
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the differential pressure feedback EGR electrical connector.
3. Disconnect the differential pressure feedback EGR hoses.
4. Remove the bolts and the differential pressure feedback EGR.
INSTALLATION
1. Fit the differential pressure feedback EGR and loosely install the bolts.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 2194
2. Tighten the bolts.
3. Connect the differential pressure feedback EGR hoses.
4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery
ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Nuts And Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 2199
Mass Air Flow Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 2200
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 2201
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 2202
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Loosen the air cleaner outlet tube clamp and position aside.
4. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation
Fuel Pressure Sensor/Switch: Description and Operation
FUEL RAIL PRESSURE SENSOR
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which
resistance changes with pressure. The electrical resistance of a strain gauge increases as
pressure increases, and decreases as pressure decreases. The varying resistance affects the
voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding
to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel
rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel
system. The differential fuel/intake manifold pressure together with measured fuel temperature
provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature
feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump
sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to
decrease.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2209
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump.
The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel
ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the
magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the
switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset
before restarting the vehicle. Refer to the Owner Guide for the location of the IFS.
Inertia Fuel Shutoff (IFS) Switch
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 2210
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery. For additional information, refer to Battery.
2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical
connector.
3. Remove the bolts and remove the IFS switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2214
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> PCM Inputs > Page 2217
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 2218
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Remove the Throttle Position (TP) sensor.
1 Disconnect the TP sensor electrical connector.
2 Remove the sensor.
NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor, Stud Bolt 19 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2223
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2224
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2225
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the CMP sensor electrical connector.
2 Remove the CMP sensor stud bolt.
3 Remove the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2229
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic
Engine Controls
Crankshaft Position Sensor: Description and Operation Electronic Engine Controls
The CKP sensor:
^ sends the PCM a signal indicating crankshaft position.
^ is essential for calculating spark timing.
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic
Engine Controls > Page 2232
Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel)
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page
2233
Crankshaft Position Sensor: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Crankshaft Position (CKP) sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor
has wear tabs that will wear off after several engine revolutions.
^ Be sure sensor wiring is routed away from the battery cable.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 2239
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Removal
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 2240
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the bearing and the gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 2241
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Note: Use a new ignition switch lock cylinder.
Follow the removal procedure in reverse order. ^
Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Bolt 25 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2245
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2246
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 2247
Knock Sensor: Service and Repair
REMOVAL
1. Remove the lower in take manifold. For additional information, refer to Engine.
2. Remove the knock sensor.
1 Remove the bolt.
2 Remove the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Specifications
Impact Sensor: Specifications
Side Crash Sensor 12 Nm
Front Crash Sensor 10.2-13.8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Driver Side Air Bag Crash Sensor
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2254
Impact Sensor: Locations Front Crash Sensors
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2255
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2256
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Locations > Driver Side Air Bag Crash Sensor > Page 2257
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front External Crash Sensor
Impact Sensor: Service and Repair Front External Crash Sensor
REMOVAL
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator grill
and radiator opening cover.
3. Remove the air bag sensor.
1 Disconnect the air bag sensor electrical connector.
2 Remove the three screws.
3 Remove the air bag sensor.
INSTALLATION
WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM
OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET
AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE
SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front External Crash Sensor > Page 2260
1. Follow the removal procedure in reverse order. 2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front External Crash Sensor > Page 2261
Impact Sensor: Service and Repair Side Crash Sensor
REMOVAL
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ Right side is shown, left side is similar.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the B-pillar lower trim panel with scuff plates.
NOTE: ^
Four door is shown, two door is similar.
^ The front seat has been removed for clarity.
3. Remove the side crash sensor.
1 Disconnect the side crash sensor electrical connector.
2 Remove the two retaining bolts.
3 Remove the side crash sensor with bracket.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Service and Repair > Front External Crash Sensor > Page 2262
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS
CRITICAL FOR PROPER SYSTEM OPERATION.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Follow the removal procedure in reverse order. 2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
2272
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Removal
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
2273
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the bearing and the gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
2274
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Note: Use a new ignition switch lock cylinder.
Follow the removal procedure in reverse order. ^
Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 2278
Neutral Safety Switch: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Component
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 2285
Ride Height Sensor: Service and Repair
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the rear jack storage area. Failure to do so may result in unexpected
inflation or deflation of the air springs which may result in shifting of the vehicle during these
operations.
1. Raise and support the vehicle. 2. Remove the spare tire
3. Disconnect the height sensor electrical connector and remove the electrical connector harness
from the frame and apron to separate the push-in
fasteners
4. Release the upper and lower spring clip and pull the sensor from the ball studs.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair
Suspension Mode Switch: Service and Repair
Removal
1. Remove the jack storage access cover.
2. Remove the retaining screw and air suspension switch bracket.
3. Remove the air suspension switch.
1 Disconnect the electrical connector.
2 Press the retaining clips and remove the air suspension switch from the bracket.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2297
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2298
Digital Transmission Range Sensor: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2299
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2300
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 2301
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 2305
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2308
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2309
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2310
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2311
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2312
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2313
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2314
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2315
Transmission Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2316
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2317
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2318
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2319
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2320
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2321
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2322
Transmission Speed Sensor: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 2323
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 2324
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2327
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2328
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2329
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2335
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2336
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2337
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2338
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2339
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2340
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2341
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2342
Transmission Temperature Sensor/Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2343
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2344
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2345
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2346
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2347
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2348
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 2349
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 2350
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 2355
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page
2358
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 2359
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
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Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2362
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2363
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 2364
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions
Four Wheel Drive Selector Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2371
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2372
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2373
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2374
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2375
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2376
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2377
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2378
Four Wheel Drive Selector Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2379
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2380
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2381
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2382
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2383
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information
and Instructions > Page 2384
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 2385
Four Wheel Drive Selector Switch: Description and Operation
Switch, Push Button 4x4 Mode
The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select
the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the
instrument cluster push button, will illuminate only when the 4x4 Low position is engaged.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 2386
Four Wheel Drive Selector Switch: Service and Repair
Removal and Installation
1. Remove and reposition the center instrument panel finish panel.
2. Disconnect the 4x4 mode switch electrical connector.
3. Remove the 4x4 mode switch.
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Specifications
Power Window Switch: Specifications
Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Power Window Switch
Power Window Switch: Diagrams Power Window Switch
2 Door
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Power Window Switch > Page 2396
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Power Window Switch > Page 2397
4 Door
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Diagrams > Page 2398
Power Window Switch: Description and Operation
The window regulator control switch:
^ Is located on each door trim panel.
^ May be used to raise or lower both LH side and RH side windows from the master control on the
driver door.
^ Includes a window lock feature that is controlled through the master control.
^ Can manually lower the driver side window when the master control is depressed longer than 0.4
seconds.
^ The driver side window can be completely lowered when the master control is depressed
between 0.04 and 0.4 seconds and then released.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch
Power Window Switch: Testing and Inspection Master Window Control Switch
Component Testing Procedure
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch > Page 2401
Terminals
Terminals
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch > Page 2402
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch > Page 2403
Schematic
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch > Page 2404
Power Window Switch: Testing and Inspection Power window Switch
Right Front
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch > Page 2405
Schematic
Left Rear
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch > Page 2406
Terminals
Schematic
Right Rear
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch > Page 2407
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Master Window Control Switch > Page 2408
Schematic
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Service and Repair > Driver Door
Power Window Switch: Service and Repair Driver Door
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the front door trim panel.
3. Remove the window regulator switch plate harness assembly.
1 Remove the screws.
2 Remove the harness assembly.
4. Remove the window regulator control switch.
1 Pry the release tabs.
2 Remove the window regulator control switch.
INSTALLATION
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Service and Repair > Driver Door > Page 2411
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Service and Repair > Driver Door > Page 2412
Power Window Switch: Service and Repair Rear Door
REMOVAL
1. Remove the rear window regulator switch plate.
1 Remove the screws.
2 Remove the rear window regulator switch plate.
2. Remove the window regulator switch plate harness assembly.
1 Remove the screws.
2 Remove the harness assembly.
3. Remove the window regulator control switch.
1 Pry the release tabs.
2 Remove the window regulator control switch.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Service and Repair > Driver Door > Page 2413
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Specifications
Windshield Washer Switch: Specifications
Windshield Wiper Washer Switch 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Specifications > Page 2418
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Multifunction Switch
Windshield Washer Switch: Diagrams Multifunction Switch
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 2421
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 2422
Windshield Washer Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 2423
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 2424
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 2425
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 2426
Windshield Washer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 2427
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations
Wiper Switch: Locations
Rear Wiper And Washer System
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Locations > Page 2431
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Multifunction Switch
Wiper Switch: Diagrams Multifunction Switch
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Multifunction Switch > Page 2434
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 2435
Wiper Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 2436
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 2437
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Diagrams > Page 2438
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Service and Repair > Rear Wiper Switch
Wiper Switch: Service and Repair Rear Wiper Switch
REMOVAL
1. Remove the instrument panel finish panel.
1 Remove the two screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
2. Remove the rear wiper/washer switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the rear wiper/washer switch.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Service and Repair > Rear Wiper Switch > Page 2441
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Service and Repair > Rear Wiper Switch > Page 2442
Wiper Switch: Service and Repair Multifunction Switch
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch >
Component Information > Service and Repair > Rear Wiper Switch > Page 2443
2 Remove the upper and lower steering column shrouds.
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Alignment Procedure Revision
Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision
TSB 04-24-19
12/13/04
REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT
HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS
FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer
Sport Trac
ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar
and coil spring front suspensions has been discontinued. If the caster and camber settings need to
be adjusted, a washer must now be installed.
The right hand upper control arm design changed from a two piece design to a single piece design
during the 2003 model year. The single piece design is now the only version of the upper control
arm available for service of prior model year Rangers.
ACTION Use the following Camber And Caster Adjustment procedure when either camber or
caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a
vehicle equipped with single piece upper control arm.
Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if
only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm.
SERVICE PROCEDURE
CAMBER AND CASTER ADJUSTMENT
NOTE
THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST
BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME
SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE
MOVEMENT OF THE UPPER ARM IN THE SLOT.
1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1).
2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is
tension, but the upper control arm can be moved for the alignment adjustment.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Alignment Procedure Revision > Page 2449
3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and
rear of the upper control arm should be made equally.
4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m).
5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for
information.
CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM
1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the
ball joint forward.
2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint
rearward.
3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m).
4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for
information.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3084 07
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Page 2450
Alignment: Specifications
Caster LH 4.2 - 1.0 deg
0 deg. Frame Angle (If vehicle is higher in the rear, add
the frame angle to the measured caster. If vehicle is
lower in the rear, subtract the frame angle from the
measured caster. Compare the total to the specification.)
RH 4.2 - 1.0 deg
Total/Split -0.7 +/- 0.5 deg
Camber LH -0.5 +/- 0.5 deg
RH -0.5 +/- 0.5 deg
Total/Split 0 +/- 0.7 deg
Toe 0.12 +/- 0.25 deg
@ Curb Ride Height (positive value is toe-in, negative
value is toe-out)
Wheel Track 0.02 in
Dogtracking 1.18 in
maximum (centerline of front tires compared to centerline
of rear tires)
Clear Vision -2.4 +/- 3.0 deg
(negative value is counterclockwise)
Front Ride Height New Vehicles With less than 500 miles 4.4 +/- 0.4 in
Original Parts 4.0 +/- 0.4 in
Replacement Parts 4.4 +/- 0.1 in
Rear Ride Height 4 Door Vehicles 5 - 5.8 in
2 Door Vehicles 4.3 - 4.8 in
Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in
Upper Ball Joint Maximum 1/32 in
Vehicle Lean Front Wheel Opening Maximum 0.6 in
Side to Side Height Differences
Rear Wheel Opening Maximum 0.78 in
Torque Specifications Caster Set Jam Nuts 129 ft lb
Front Suspension Upper Arm Cam Nuts 98 ft lb
Toe Set Jam Nuts 59 ft lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber
Alignment: Description and Operation Camber
Negative and Positive Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
2453
Alignment: Description and Operation Caster
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
2454
Alignment: Description and Operation Dogtracking
Dogtracking
Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned
roads can give the illusion of dogtracking.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
2455
Alignment: Description and Operation Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the
steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
2456
Alignment: Description and Operation
Camber
Negative and Positive Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Dogtracking
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
2457
Dogtracking
Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned
roads can give the illusion of dogtracking.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the
steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
General Information
Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting
bolts. Toe is adjusted by the use of the front wheel spindle tie-rod.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces and observed by the driver as small rotational oscillations of the steering wheel.
Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as
the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20° of steering wheel turn). Efforts may be said to be "flat on center." ^
Under 20° of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the
steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the
self-aligning forces at the road wheel or tire patch.
^ In the diagnosis of a readability problem, it is important to understand the difference between
wander and poor groove feel.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe the poor return of the steering wheel to
center after a turn or the steering correction is completed.
Ride Height
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
2458
Front Ride Height Measurement
Rear Ride Height Measurement
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced
near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or
irregularities in the road surface.
Toe
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Camber > Page
2459
Positive Toe (Toe In)
Positive Toe (Toe In)
Negative Toe (Toe Out)
Negative Toe (Toe Out)
The vehicle toe setting: ^
affects tire wear and directional stability.
^ must be checked after adding aftermarket equipment, such as a snowplow or body.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment
Alignment: Service and Repair Camber and Caster Adjustment
1. Remove the nuts and alignment plates.
2. Install the cams and the nuts.
3. Note: A pry bar can be used between the front suspension arm bushing joint and the frame
pocket to aid in moving the farm.
To increase the LF caster and camber, use the following steps. 1
To increase caster, move the front of the front suspension arm bushing joint outboard and move
the rear of the front suspension arm bushing joint inboard.
2 To increase camber, move the front suspension arm bushing joint outboard equally.
4. To decrease the LF caster and camber, use the following steps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2462
1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move
the rear of the front suspension arm bushing joint outboard.
2 To decrease camber, move the front suspension arm bushing joint inboard equally.
5. Tighten the nuts.
6. Note: A pry bar can be used between the front suspension arm bushing joint and the frame
pocket to aid in moving the arm.
To increase RF caster and camber, use the following steps. 1
To increase caster, move the front of the front suspension arm bushing joint outboard and move
the rear of the front suspension arm bushing joint inboard.
2 To increase camber, move the front suspension arm bushing joint outboard equally.
7. To decrease the RF caster and camber, use the following steps.
1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move
the rear of the front suspension arm bushing joint outboard.
2 To decrease camber, move the front suspension arm bushing joint inboard equally.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2463
8. Increase the caster split.
1 Loosen the nuts.
2 Adjust the caster set bolts forward.
9. Decrease the caster split.
1 Loosen the nuts.
2 Adjust the caster set bolts rearward.
10. Tighten the nuts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2464
Alignment: Service and Repair Ride Height
Ride Height - Front Suspension
1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to
normalize the vehicle static ride height.
3. Measure the distance between the center line of the front suspension lower arm bushing bolt
and the lift. Record the measurement.
4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the
measurement.
5. Determine ride height.
^ Subtract measurement
1 from measurement
2. This is the ride height.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2465
6. Note: The torsion bar adjusting bolt is coated with adhesive that wears; off after disassembly. If
the torsion bar system is ever disassembled or the
torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when
re-assembling.
Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting
bolt. ^
Tighten the torsion bar adjusting bolt to increase the torque or raise the height.
^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height.
Ride Height - Vehicle Dynamic Suspension
Special Service Tool(s)
1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT
screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle
to its
lowest attainable height: ^
REAR FILL (rear fill solenoid).
^ GATE VALVE (gate solenoid).
^ VENT (vent solenoid).
3. Close all doors including the liftgate and liftgate window. 4. Reopen any door (to ensure that the
height will not change until the internal electronic calibration is complete). 5. Park the vehicle on a
flat surface. 6. From the function menu, quickly select RIDE HEIGHT CALIBRATION. 7. Note the
warning on the scan tool screen and follow the directions. 8. Lower the vehicle and clear all stored
Diagnostic Trouble Codes (DTCs).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2466
Alignment: Service and Repair Toe Adjustment
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake
pedal.
3. Check the toe settings; follow the manufacturer's instructions.
4. Note: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod (3280)
is rotated.
Remove the clamps.
5. Loosen the nuts.
^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber and Caster
Adjustment > Page 2467
6. Rotate the front wheel spindle tie-rods.
7. Tighten the nuts.
8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Specifications
Fuel Pressure Test Port: Specifications
Fuel Pressure Relief Valve Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information > Page 2475
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 2476
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 2477
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel
supply line.
3. Remove the four bolts and the fuel supply line from the fuel supply manifold.
4. Remove the fuel supply line bracket bolt and the fuel supply line.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G, to aid installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications > With 104 Pin Processor
Idle Speed: Specifications With 104 Pin Processor
Hot Idle ................................................................................................................................................
......................................................... 670 - 750 RPM
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information >
Specifications > With 104 Pin Processor > Page 2482
Idle Speed: Specifications With 150 Pin Processor
With Automatic Transmission
Hot Idle ................................................................................................................................................
.................................................................. 750 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
.................................................................. 750 RPM
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Component
Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 2490
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL SERVICE TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure.
NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 2491
Fuel Pressure Gauge
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order: Specifications
Coil Terminal-To-Cylinder Relationship
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications > Page 2495
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions
Ignition Cable: Service Precautions
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions > Page 2503
Ignition Cable: Service and Repair
Spark Plug Wire Remover
SPECIAL SERVICE TOOL(S)
REMOVAL
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug.
2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the
ignition coil.
3. Remove the spark plug wires.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service Precautions > Page 2504
1. To install, reverse the removal procedure.
CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the
exhaust manifold.
NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or
equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug and ignition
coil boots of the spark plug wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Spark Plug Gap
Spark Plug: Specifications
Spark Plug Gap 1.3 - 1.4 mm
RH Original Spark Plug AGRF22PG
LH Original Spark Plug AGRF22P
New Spark Plug (Either Side) AGSF22PP
Spark Plugs 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Spark Plug Gap > Page 2509
Spark Plug: Specifications
Spark Plug Gap 1.3 - 1.4 mm
RH Original Spark Plug AGRF22PG
LH Original Spark Plug AGRF22P
New Spark Plug (Either Side) AGSF22PP
Spark Plugs 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2510
Spark Plug: Application and ID
RH Original Spark Plug Type ..............................................................................................................
.............................................................. AGRF22PG LH Original Spark Plug Type ............................
....................................................................................................................................................
AGRF22P New Spark Plug Type (Either Side) ...................................................................................
................................................................................. AGSF22PP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 2511
Spark Plug: Service and Repair
REMOVAL
1. Remove the spark plug wires. For additional information, refer to Ignition Cable.
2. Remove the spark plugs.
NOTE: ^
Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from.
New spark plugs can be used in any cylinder.
3. Inspect the spark plugs.
4. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading. For additional information, refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2515
Compression Check: Testing and Inspection
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE
5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top
of the pistons in the low-reading cylinders. Repeat the compression pressure check on these
cylinders.
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 2516
2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent
cylinders indicate low compression pressures and squirting oil on each piston does not increase
compression, the head gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
The 4.0L Push Rod engine has hydraulic lifters and requires no valve clearance adjustments.
The 4.0L SOHC engine:
- Manufacturer does not indicate whether the type of valve arrangement for this engine.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2523
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Locations > Page 2524
Drive Belt: Description and Operation
The accessory drive system consists of the following: drive belt
- generator
- power steering pump
- A/C compressor
- water pump pulley
- drive belt tensioner
- belt idler pulley
- crankshaft pulley
The accessory drive: has a single serpentine drive belt (six ribs).
- has an automatic tensioner.
- is not adjustable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical concerns apply: 3. Inspect for drive belt
cracking/chunking/wear. 4. If the concerns remain after inspection, determine the symptoms and go
to the symptom chart.
Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can
occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern.
- has no detrimental effect on drive belt performance.
Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib
chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the
cracks. The drive belt should be replaced if chunking occurs.
V-Ribbed Belt With Cracks (Acceptable)
V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable)
5. If the concern(s) remains after inspection, determine the symptoms and go to the Symptom
Chart.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 2527
Drive Belt: Symptom Related Diagnostic Procedures
1 of 2
2 of 2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Initial Inspection
and Diagnostic Overview > Page 2528
Drive Belt: Component Tests and General Diagnostics
Belt Tensioner
The automatic drive belt tensioner can be checked as follows: 1. With the engine running, observe
the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C
clutch cycles
or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without
A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In
rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause
excessive drive belt tensioner movement. This condition can he checked by installing the suspect
drive belt with a known good original equipment drive belt and repeating the observation.
Drive Belt Misalignment
CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the
drive belt to come off the drive pulleys.
Note: Original equipment drive belts are made of a special cord construction and are subjected to
special testing before they are approved for use.
Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks
incorrectly, install a new original equipment drive belt to avoid performance failure or loss of drive
belt. With the engine running, check drive belt tracking (the position of the drive belt on one of the
grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge
of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually
check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt
tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface
pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal
noises. If the above procedures do not correct the drive belt noise, install a new drive belt.
However, the drive belt noise may return (with mileage) if one of the above conditions still exists
uncorrected. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for
excessive wobble. Install new components as required.
- Check all accessories, mounting brackets and drive belt tensioner, for any interference that would
prevent the component from mounting properly. Correct any interference condition and recheck
belt tracking.
- Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to
specification. Recheck drive belt tracking.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 2529
Drive Belt: Service and Repair
Removal and Installation
1. Remove the air cleaner outlet tube.
2. Remove the drive belt.
1 Rotate the drive belt tensioner counterclockwise.
2 Remove the drive belt.
3. Note: Refer to Component Locations for proper drive belt routing. See: Locations
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Component Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and
Repair
Evaporative Canister Filter: Service and Repair
REMOVAL
1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For
additional information refer to Battery.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
3. Disconnect the two chassis emissions lines from the evaporative emission tube.
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
4. Remove the evaporative emissions canister bolts.
5. Remove the evaporative emission canister with bracket assembly.
1 Disconnect the canister vent solenoid electrical connector.
2 Remove the EVAP canister with bracket assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Evaporative Canister Filter > Component Information > Service and
Repair > Page 2540
6. Disconnect the canister vent hose.
7. Remove the evaporative emission dust separator.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emission system. For additional information, refer to Evaporative
Emission System Leak Test. See: Powertrain Management/Emission Control Systems/Evaporative
Emissions System/Testing and Inspection/Component Tests and General Diagnostics/Component
Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer
to Evaporative Emission Repair Verification Drive Cycle. See: Powertrain Management/Emission
Control Systems/Evaporative Emissions System/Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications
Fluid Filter - A/T: Specifications
Transmission fluid filter screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2544
Fluid Filter - A/T: Service and Repair
Removal
1. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
- Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan bolts. Pry the rear of the transmission fluid pan down and allow fluid to drain.
After fluid is drained remove the front two transmission fluid pan bolts.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2545
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V; Automatic Transmission Fluid
XT-5-QM meeting Ford specification
MERCON(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2546
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
- Use a crisscross sequence to tighten the transmission fluid pan screws.
6. Position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle.
8. Note: When filling a dry transmission and converter start with a minimum of 3.7 liters (4 quarts).
Fill transmission to the proper fluid level and check for proper transmission operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Specifications > Page 2547
- Use MERCON V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON
V.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions > Page 2552
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL SERVICE TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure.
NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
Precautions > Page 2553
Fuel Pressure Gauge
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications
Oil Filter: Specifications
Oil bypass filter 10 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2566
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page 2567
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
2573
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
2574
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Page 2575
Heater Hose: Specifications
Heater hose bracket bolts 27 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Technical Service Bulletins >
Page 2576
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications
Hose/Line HVAC: Specifications
Peanut Fitting Nut 7-9 Nm
A/C Line To Condenser Nut 6.8-9.2 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page
2580
Hose/Line HVAC: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C
evaporator core orifice.
The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the
following features:
- The upstream side contains low pressure refrigerant gas.
- The downstream side contains high pressure refrigerant gas and a fitting used to mount a
serviceable high-pressure A/C charge port valve.
- The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A
long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off
switch can be removed without discharging the A/C system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page
2581
Hose/Line HVAC: Service and Repair
REMOVAL
1. Perform the Refrigerant Discharging and Recovery Procedure.
2. Disconnect the condenser to evaporator tube from the A/C condenser core.
3. Disconnect the condenser to evaporator tube spring lock coupling from the A/C evaporator core
and remove the condenser to evaporator tube.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Specifications > Page
2582
Spring Lock Coupling
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications
Power Steering Line/Hose: Specifications
Pressure Hose to Power Steering Pump 48 ft.lb
Power Steering Pump Bolts 18 ft.lb
Steering Gear Pressure Fittings 22 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications >
Page 2586
Power Steering Line/Hose: Service and Repair
Special Tools
Special Service Tool(s)
Removal
1. Refer to the Description and Operation for the hose routing and retention points.
Installation
1. When connecting a fitting with a seal ring, a new seal ring must be installed.
^ The special tool is used to install the return line connector seal and the pressure line connector
seal.
2. Fill and leak check the system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
Brake Fluid High Performance DOT 3
Dot 4 may be used if Dot 3 is not available.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 2591
Brake Fluid: Description and Operation
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid
meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford
vehicles. ^
Do not reuse brake fluid drained or bled from the system.
^ Do not use brake fluid that has been stored in an open container.
^ Do not use contaminated brake fluid.
^ Do not mix different types of brake fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Clutch Fluid > Component Information > Specifications
Clutch Fluid: Specifications
Clutch Fluid Type DOT-3 Brake Fluid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine Coolant - Propylene Glycol Recommendations
Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations
Article No. 01-23-6
11/26/01
^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON
ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL
^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION
ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS
FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002
CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR
2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO
1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002
EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F
SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER
SPORT 2000-2002 F-650, F-750
LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD
MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE
1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002
VILLAGER 1997-2002 MOUNTAINEER
MERKUR: 1989 SCORPIO, XR4TI
This article is being republished in its entirety to update the model year coverage.
ISSUE This TSB article describes Ford Motor Company's position on the use of propylene
glycol-based engine coolants.
ACTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins >
Engine Coolant - Propylene Glycol Recommendations > Page 2599
Ford Motor Company does not recommend nor endorse the use of engine coolants made with
propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene
glycol-based engine coolants.
Published information suggests that engine coolants made with propylene glycol may provide
engine cooling performance equivalent to engine coolants made with ethylene glycol. However,
different brands of engine coolant provide varying corrosion protection for the cooling system. Ford
does not have performance data for the multitude of engine coolants available in the aftermarket
and therefore cannot recommend the use of any coolant except those sold by Ford Customer
Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer
Service Division coolant for the vehicle.
Furthermore, claims of toxicological and environmental advantages of propylene glycol over
ethylene glycol may be misleading. When significant new information is developed, Ford will review
this policy.
Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene
glycol-based engine coolants. Those specifications do not refer to engine coolants made with
propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon
the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its
components, the cost of repairing the damage would not be covered by the Ford New Vehicle
Limited Warranty.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 402000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
Coolant Capacity 16.3 qt (US)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 2602
Coolant: Fluid Type Specifications
Antifreeze Type Ford Premium Engine Coolant (Green in color)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid ..............................................................................................................................
..................................................................... 10.3 qts Note: Approximately Dry Fill Capacity
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 2607
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
Type .....................................................................................................................................................
............................................................. MERCON V
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan,
Gasket and Filter
Fluid - A/T: Service and Repair Fluid Pan, Gasket and Filter
Fluid Pan, Gasket and Filter
Removal
1. Raise and support the vehicle.
NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail
and positioned out of the way for fluid pan removal.
If equipped, loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
- Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove
the converter.
- Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to
drain. After fluid is drained, remove the front two transmission fluid pan screws.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan,
Gasket and Filter > Page 2610
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid
XT-5-QM meeting Ford specification MERCON
(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter.
^
Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan,
Gasket and Filter > Page 2611
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the
vehicle.
8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
Fill transmission to the correct fluid level and check for correct transmission operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan,
Gasket and Filter > Page 2612
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification
MERCON(R) V.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan,
Gasket and Filter > Page 2613
Fluid - A/T: Service and Repair Drain and Refill W/Automated Equipment
Transmission Fluid Drain and Refill-Automated Equipment
Special Tool(s)
Draining
CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission
fluid additives, treatments or cleaning agents. The use of these materials can affect the operation
of the transmission, resulting in internal component failure.
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: This is a new procedure for draining and adding transmission fluid using a suitable
transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a
suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine,
connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will
help remove any foreign material trapped in the fluid coolers.
4. Carry out the fluid exchange process.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the
vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission fluid level
and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the
correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan,
Gasket and Filter > Page 2614
Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug
Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug
Draining
CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission
fluid additives, treatments or cleaning agents. The use of these materials can affect the operation
of the transmission, resulting in internal component failure.
1. With the vehicle in PARK, position on a hoist.
2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail
and positioned aside for fluid pan removal.
If equipped, loosen the nut and position the heat shield aside.
3. Place a drain pan under the transmission fluid pan.
4. Drain the transmission fluid.
^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to
drain. After the fluid is drained, remove the front two transmission fluid pan screws.
5. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan,
Gasket and Filter > Page 2615
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces.
Refill
1. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan
^ Loosely install the transmission fluid pan screws.
2. Tighten the transmission fluid pan screws.
^ Tighten the transmission fluid pan screws in a crisscross sequence.
3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the
vehicle.
5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
With the engine running and the transmission at normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is
needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should
be in the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid Pan,
Gasket and Filter > Page 2616
cross-hatched area of the fluid level indicator).
6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the
gears. 8. Check the transmission fluid level.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
M/T - Mercon(R) V ATF Usage Information
Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information
TSB 06-26-1
01/08/07
MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME
MANUAL TRANSMISSIONS
FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco
1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super
Duty 2001-2003 Explorer Sport Trac, Explorer Sport
LINCOLN: 2001-2002 Lincoln LS
MERCURY: 1984-1995 Cougar 1987-1999 Tracer
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the
service fluid for manual transmissions originally requiring MERCON(R).
ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can
now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual
usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic
Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue
until remaining inventory has been depleted.
SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
M/T - Mercon(R) V ATF Usage Information > Page 2621
Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper
fluid application on current and past model manual transmissions refer to the fluid usage chart.
(Figure 1)
WARNING
FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR
OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT
(XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS
RECOMMENDING THAT PARTICULAR FLUID.
USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins >
M/T - Mercon(R) V ATF Usage Information > Page 2622
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Specifications
Fluid - M/T: Capacity Specifications
Manual Transmission
Capacity ...............................................................................................................................................
................................................................... 2.7 Quarts Note: Approximate refill. Service refill
capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a
level surface.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Specifications > Capacity
Specifications > Page 2625
Fluid - M/T: Fluid Type Specifications
Manual Transmission Fluid ..................................................................................................................
............................................................. Mercon ATF
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications
Fluid - Differential: Capacity Specifications
Front
Differential Oil Capacity
Refill .....................................................................................................................................................
......................................................................... 1.8 qt
Rear
Differential Oil
Capacity ...............................................................................................................................................
.......................................................... 2.4L (55 pints)
6.4 mm (0.25 in) - 14.2 mm (0.56 in) below the fill hole
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Capacity
Specifications > Page 2630
Fluid - Differential: Fluid Type Specifications
Front
Differential Fluid Type
Type .....................................................................................................................................................
..................................................................... 80W-90
Rear
Differential Fluid Type
Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C197-A for 4.0L SOHC and 4.0L EI with a conventional differential.
Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting
Ford specification WSL-M2C192-A for 4.0L SOHC and 4.0L EI with a limited slip differential and
5.0L.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Bulletins > Customer Interest for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks
Fluid - Transfer Case: Customer Interest Front Axle - Vent Tube Fluid Leaks
Article No. 01-8-6
4/30/01
^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4
OR AWD
^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH
4X4 OR AWD
FORD: 1995-2001 EXPLORER 1997-2001 RANGER
MERCURY: 1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model applications and model
years.
ISSUE
Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer
Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by
the gears during vehicle operation.
ACTION
Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover
has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle
operation. Refer to the Instruction Sheet included in the kit and the following text for details.
The Cover Kit (F6TZ-4033-BA) includes the following:
^ One (1) Cover One (1) Hose
^ One (1) Hose Connector One (1) Vent Plug One (1) Clip
^ One (1) Sealant
^ One (1) Instruction Sheet
NOTE
SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND
BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
010806A Install Axle Cover kit 1.7 Hrs.
DEALER CODING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Bulletins > Customer Interest for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid Leaks > Page
2639
CONDITION
BASIC PART NO. CODE
4022 D1
OASIS CODES: 509000, 510000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid
Leaks
Fluid - Transfer Case: All Technical Service Bulletins Front Axle - Vent Tube Fluid Leaks
Article No. 01-8-6
4/30/01
^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4
OR AWD
^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH
4X4 OR AWD
FORD: 1995-2001 EXPLORER 1997-2001 RANGER
MERCURY: 1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model applications and model
years.
ISSUE
Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer
Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by
the gears during vehicle operation.
ACTION
Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover
has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle
operation. Refer to the Instruction Sheet included in the kit and the following text for details.
The Cover Kit (F6TZ-4033-BA) includes the following:
^ One (1) Cover One (1) Hose
^ One (1) Hose Connector One (1) Vent Plug One (1) Clip
^ One (1) Sealant
^ One (1) Instruction Sheet
NOTE
SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND
BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
010806A Install Axle Cover kit 1.7 Hrs.
DEALER CODING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube Fluid
Leaks > Page 2645
CONDITION
BASIC PART NO. CODE
4022 D1
OASIS CODES: 509000, 510000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Case Capacity .......................................................................................................................
.................................................................... 1.5 Quarts
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 2648
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case Fluid
Type .....................................................................................................................................................
............................................................. Mercon ATF
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications
Technical Service Bulletin # 02-1-9 Date: 020121
Engine Oil - Oil Recommendations/Applications
Article No. 02-1-9
01/21/02
ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30
MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY
FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002
ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002
FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER
1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002
LS 1998-2002 NAVIGATOR
MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999
TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001
MOUNTAINEER
This article is being republished in its entirety to update the vehicle models, engines and years
affected.
NOTE
PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A
COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB.
ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most
gasoline and flexible fueled vehicles.
ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the
recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to
improve fuel economy.
Testing has validated this viscosity grade can be used in many previous model year vehicles. It is
recommended ALL vehicles on the following Vehicle Application Listing be service with SAE
5W-20.
All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002
Vehicles" chart are being filled with SAE 5W-20
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 2653
motor oil at the factory and should also be serviced with SAE 5W-20 oil.
Exception 2001 Vehicles
Exception 2002 Vehicles
NOTE
IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED.
REFER TO TSB 99-8-16.
Parts Block
OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000
Veh. App. Listing Approved For SAE 5W-20 Motor Oil
^ 1993-1996 1.9L Escort/Tracer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 2654
^ 1995-2000 2.0L Zetec Contour/Mystique
^ 1999-2002 2.0L Cougar
^ 1997-2002 2.0L Escort/Tracer
^ 1998-2002 2.0L Escort ZX2
^ 2000-2002 2.0L Focus
^ 2001-2002 2.0L Escape
^ 1993-1997 2.3L Ranger
^ 1993-1994 2.3L Mustang
^ 1993-1994 2.3L Tempo/Topaz
^ 1998-2001 2.5L Ranger
^ 1995-2000 2.5L Contour/Mystique
^ 1999-2002 2.5L Cougar
^ 2001-2002 3.0L 4V Escape
^ 1996-2001 3.0L 4V Taurus/Sable
^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger,
^ Taurus/Sable (Flexible Fuel and Gas)
^ 1995-2000 3.0L (Vulcan) Windstar
^ 1993-1994 3.0L (Vulcan) Tempo/Topaz
^ 2000-2002 3.0L 4V Lincoln LS
^ 1995-2002 3.8L Windstar
^ 1993-1997 3.8L Taurus/Sable,
^ Thunderbird/Cougar, Continental
^ 1994-2002 3.8L Mustang
^ 2002-2002 3.9L 4V Lincoln LS
^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series
^ 1996-2002 4.6L 2V Mustang
^ 1992-2002 4.6L Crown Victoria/Grand Marquis
^ 1991-2002 4.6L Town Car
^ 1994-1997 4.6L 2V Thunderbird/Cougar
^ 1996-2002 4.6L 4V Mustang Cobra
^ 1995-2002 4.6L 4V Continental
^ 1993-1998 4.6L 4V Mark VIII
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins >
Engine Oil - Oil Recommendations/Applications > Page 2655
^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition
^ 1993-1999 4.9L E-Series, F-Series
^ 1993-1995 5.0L Mustang/Mustang Cobra
^ 1993-1993 5.0L Thunderbird/Cougar
^ 1997-2001 5.0L Explorer/Mountaineer
^ 1993-1996 5.0L E-Series, F-Series, Bronco
^ 2000-2002 5.4L Excursion
^ 1998-2002 5.4L 2V/4V Navigator
^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350
Chassis/RV/Cutaway
^ 1993-1997 5.8L F-Series, Bronco
^ 1993-1996 5.8L E-Series
^ 2000-2002 6.8L Excursion
^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway
^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome
^ 1993-1998 7.5L All Vehicles
NOTE
FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV.
NOTE
THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR
OIL
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................
............................................................. 4.7L (5.0 Qt)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 2658
Engine Oil: Fluid Type Specifications
Engine Oil Type ...................................................................................................................................
............................................... SAE 5W-30 Motor Oil
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Mercon V(R) Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage
TSB 07-1-7
01/22/07
MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER
STEERING SYSTEMS
FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort
2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle
2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53
Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005
Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007
Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series
2000-2007 F-650, F-750 2006-2007 Low Cab Forward
LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln
LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator
2006-2007 Mark LT 2007 MKX
MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar
2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002
Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid for power steering systems originally requiring MERCON(R).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Mercon V(R) Fluid Usage > Page 2663
ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be
serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids
labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission
Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining
inventory has been depleted.
SERVICE PROCEDURE
Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V.
CAUTION
APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER
STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY
OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Page 2664
Power Steering Fluid: Specifications /
/
Power Steering Fluid Type MERCON(R) ATF
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
System Capacity 30 oz (US)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 2669
Refrigerant: Fluid Type Specifications
Refrigerant Type Ford YN-19 (R-134a)
Specification WSH-M17B19-A
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2670
Refrigerant: Service Precautions
The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a
protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun.
Ozone Depletion Scientific research performed over the past 15 years links the release of
chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone
depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer
located in the stratosphere where they react with and destroy ozone molecules.
Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown
to lead to higher incidents of cancer as well as global warming. When viewed from a global
perspective, ozone depletion holds an enormous potential for damage.
Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of
the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial
but the same compound, when located at ground level, is harmful to humans, animals, crops and
vegetation.
Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with
nitrogen oxides (NOx) in the presence of sunlight and heat.
Montreal Protocol In response to the growing body of evidence demonstrating the detrimental
effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to
establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become
signatories to this agreement leading to an end of production of R12 in December, 1995, in all
developed countries.
As established by the Montreal Protocol, R12 production in developed countries has ceased.
Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned
production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to
control both the production and use of (CFC)s for refrigerant applications including mobile vehicle
air conditioning systems.
Additional Information Sources
For more complete and detailed explanations of the above policies, please refer to:
http://www.epa.gov/ozone/
Technician Certification Organizations providing technician refrigerant recovery and recycling
certification include:
National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2
Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/
International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX
76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/
Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041
Phone: 215-679-2220
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2671
Fax: 215-541-4635 http://www.macsw.org/
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 2672
Refrigerant: Service and Repair
SPECIAL SERVICE TOOL(S)
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For
additional information, refer to Refrigerant
Identification Testing. See: Heating and Air Conditioning/Testing and Inspection/Component Tests
and General Diagnostics/Identifying Refrigerants
2. Connect the R-134a A/C refrigerant center to the low and high-pressure service gauge port
valves.
NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. For additional
information, refer to Manifold Gauge Set Connection. See: Heating and Air Conditioning/Service
and Repair/Manifold Gauge Set Connection
3. Perform the Refrigerant Discharging and Recovery Procedure. 4. Once the refrigerant center
has recovered the vehicle A/C system refrigerant, close the refrigerant center inlet valve (if so
equipped). Then switch
off the power supply.
5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system
vacuum level as shown on the gauge. If the pressure
does not rise, disconnect the recovery station hose(s).
6. If the system pressure rises, repeat steps 2 through 5 until the vacuum level remains stable for
two minutes. 7. Carry out the required repairs, then Perform the Evacuation and Charging
Procedure. For additional information, refer to Evacuation and
Charging. See: Heating and Air Conditioning/Service and Repair/Evacuation and Charging
Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
System Capacity 9 oz (US)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 2677
Refrigerant Oil: Fluid Type Specifications
Lubricant PAG Compressor Oil
Type YN-12c
Part Number F7AZ-19589-DA
Specification WSH-M1C231-B
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2678
Refrigerant Oil: Service and Repair
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and small amount is retained in each component. If certain components of the system are
removed, some of the refrigerant oil will go with the component. To maintain the original total oil
charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour
the same amount plus 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or
equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5
ounces), pour the same amount drained of clean PAG compressor oil YN-12-C F7AZ-19589-DA or
equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces),
pour 85 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B into the new A/C compressor.
NOTE: Service A/C compressors are shipped without compressor oil.
2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier
cylinder and drain the oil into a calibrated container.
- Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml
(2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford
specification WSH-M1C231-B.
3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG compressor oil YN-12-C
F7AZ-19589-DA or equivalent meeting Ford
specification WSH-M1C231-B to the suction accumulator/drier inlet tube.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page 2679
4. For the A/C condenser core , add 30 ml (1 ounce) of clean PAG compressor oil YN-12-C
F7AZ-19589-DA or equivalent meeting Ford
specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet
tube.
5. Add 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B to the
suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice.
- installation of a new A/C compressor pressure relief valve.
- installation of a new refrigerant line.
- repair of an O-ring seal leak.
- repair of a charge port leak.
6. Installation of new components that do not require discharge of refrigerant and resulting oil loss,
such as the A/C cycling switch and the A/C
pressure transducer, do not require additional oil.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications
Brake Bleeding: Specifications
Caliper bleeder screw, rear 15 ft.lb
Caliper bleeder screw, front 15 ft.lb
Master cylinder bleeder screw 70-159 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding
Brake Bleeding: Service and Repair Brake Caliper Bleeding
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw. Refer to Specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2685
Brake Bleeding: Service and Repair Brake System Manual Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the
tube in a container partially filled with clean brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear bleeder screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2686
6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw.
7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH front disc brake caliper bleeder
screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9.
Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While
the assistant maintains pressure on the brake
pedal, tighten the RH front disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the
LH front disc brake caliper bleeder screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2687
Brake Bleeding: Service and Repair Brake System Pressure Bleeding
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front disc brake caliper bleeder screw ending
with the LH front disc brake caliper bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2688
Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU)
NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS)
hydraulic control unit (HCU) has been installed new.
1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash, and follow the scan tool instructions for
bleeding.
2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container
partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then
hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake
fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the
bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front
bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed
procedure as outlined in Steps 3 - 7.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2689
Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench
Special Tools
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air
can get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When the brake master cylinder has been installed new or the system has been emptied or
partially emptied, it must be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2690
2. For bench priming, mount the brake master cylinder in a vise.
3. Install short brake tubes with the ends bent into the brake master cylinder reservoir.
^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.
4. For a new brake master cylinder, remove the cruise switch.
5. Fill the cruise switch with the specified brake fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2691
6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an
assistant slowly pump the brake pedal until clear brake fluid flows from both
brake tubes with no air bubbles.
8. If necessary, install the brake master cylinder into the vehicle.
9. Remove the short brake tubes and install the master cylinder outlet tubes.
10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU).
11. NOTE: Refill the brake master cylinder reservoir as necessary.
Have an assistant depress and hold the brake pedal.
12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles
are seen in the expelled brake fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Brake Caliper
Bleeding > Page 2692
14. Repeat the above four steps for the remaining master cylinder outlet tube.
15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other
end in a container partially filled with the specified
brake fluid.
16. Have an assistant pump and then hold firm pressure on the brake pedal.
17. NOTE: Refill the brake master cylinder reservoir as necessary.
Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube.
18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no
air bubbles in the expelled brake fluid. 20. Bleed the brake system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Page 2693
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2698
7. Remove the two steering wheel back cover plugs.
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2699
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2700
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2701
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2702
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming and Arming > Page 2703
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Prove out the system means to turn the ignition switch from the OFF to the RUN position and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately six seconds and then turn off. If an air bag Supplemental
Restraint System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2709
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2710
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2711
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2712
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2713
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2714
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2715
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2716
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2717
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2718
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2719
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions
Fuse: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2722
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2723
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2724
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2725
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Diagram Information and Instructions > Page 2726
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Diagrams >
Diagram Information and Instructions > Page 2727
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Diagram Information and Instructions > Page 2728
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Diagram Information and Instructions > Page 2729
Fuse: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Diagram Information and Instructions > Page 2730
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Diagram Information and Instructions > Page 2731
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Diagram Information and Instructions > Page 2733
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Diagram Information and Instructions > Page 2734
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Diagram Information and Instructions > Page 2735
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2738
Fuse 1 - 18
Fuse 19 - 36
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2739
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2740
Fuse 1 - 10
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2741
Fuse 11 - 31
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2742
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Application and
ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2743
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2744
Fuses
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2745
Relays
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2746
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2747
Fuses
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ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2748
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2753
Fuse 1 - 18
Fuse 19 - 36
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2754
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2755
Fuse 1 - 10
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2756
Fuse 11 - 31
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Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2757
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations
> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2758
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2759
Fuses
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2760
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2761
Battery Junction Box (BJB) / Power Distribution Box
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2762
Fuses
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> Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2763
Fuses
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Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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> Diagram Information and Instructions > Page 2766
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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> Diagram Information and Instructions > Page 2768
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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> Diagram Information and Instructions > Page 2769
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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> Diagram Information and Instructions > Page 2770
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> Diagram Information and Instructions > Page 2771
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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> Diagram Information and Instructions > Page 2773
Fuse Block: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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> Diagram Information and Instructions > Page 2774
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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> Diagram Information and Instructions > Page 2775
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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> Diagram Information and Instructions > Page 2776
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2777
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2778
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams
> Diagram Information and Instructions > Page 2779
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2782
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2783
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2784
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2785
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2786
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2787
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2788
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2789
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2790
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2791
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2792
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2797
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2798
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2799
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2800
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2801
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2802
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2803
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2804
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2805
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2806
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2807
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Relay Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Relay Module > Page 2810
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Relay Module > Page 2811
Relay Box: Diagrams Auxiliary Relay Box #2
2 Door W/o Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Relay Module > Page 2812
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams >
Relay Module > Page 2813
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2816
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2817
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2818
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2819
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2820
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2821
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2822
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2823
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2824
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2825
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application
and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 2826
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component
Information > Locations > Page 2831
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR LAMP (MIL)
Malfunction Indicator Lamp (MIL)
Check Engine, Service Engine Soon Or ISO Standard Engine Symbol
The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control
Module (PCM) has detected an OBD II emission-related component or system fault. When this
occurs, an OBD II Diagnostic Trouble Code (DTC) will be set.
^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or ISO standard engine symbol (Figure 16).
^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position.
^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster
proveout for approximately 4 seconds.
^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present.
- The instrument cluster will illuminate the MIL if the PCM does not send a control message to the
instrument cluster.
- The PCM is operating in the Hardware Limited Operation Strategy (HLOS).
- The MIL circuit is shorted to ground.
^ If the MIL remains off (during the bulb check): Bulb is damaged.
- MIL circuit is open.
^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three
consecutive drive cycles must be completed without a fault.
^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection.
^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist.
^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground
in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Description and Operation
Oil Change Reminder Lamp: Description and Operation
If the connection to the oil temperature sensor is open circuit or shorted, the message center
display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE
LEFT during system cheek sequence.
One of these warning messages is displayed when the engine oil life remaining is five percent or
less.
- When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message
will be displayed.
- When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be
displayed.
The message center indicator will indicate the percent of oil life remaining during System Check.
This percentage is based on the driving history and the time since the last oil change. In order to
ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET
procedure, as described in the Owner's Guide, after an oil change.
To calculate the percentage of oil life remaining, the oil life feature uses:
- oil temperature sensor input
- tachometer input from the PCM
- vehicle speed signal input
- clock time (maintained internally by the message center)
- The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or
6 months. It will reach zero percent sooner under different driving conditions.
- The percentage of oil life remaining is the second display in the system check sequence.
- When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON"
message will be displayed.
- When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be
displayed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Description and Operation > Page 2835
Oil Change Reminder Lamp: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component
Information > Description and Operation > Page 2836
Oil Change Reminder Lamp: Service and Repair
Oil Change Reset
Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized
oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of
12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL
CHANGE RESET control for five seconds. The message center will count down for five seconds.
After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have
established a personalized oil reset percentage, the display will show that percentage instead of
100%.) This reset procedure should be performed only after an oil change to ensure accurate oil
life indications.
Your personalized oil reset percentage allows you to establish a smaller oil change interval than
the manufacturer's recommended interval. To establish your personalized oil reset percentage:
1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display
is still counting gown the five seconds to
reset. The display will change to START OIL LIFE AT XXX%.
2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil
reset percentage you desire. Your choices are
100%, 90%, 80%, 70%, 60%, 50% 40% and 30%.
3. Press the RESET control to complete the procedure. Pressing any control other than RESET of
OIL CHANGE RESET will abort this
procedure and will not establish your new personalized oil reset percentage.
When your personalized oil reset percentage has been established, it will be used beginning with
the completion of your next OIL CHANGE RESET procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component
Information > Description and Operation
Oil Level Warning Indicator: Description and Operation
This warning message is displayed when the engine oil level is low.
When the engine oil level is normal, the input to the message center indicator will be an open
circuit.
When the engine oil level is low, the low oil level sensor will close, grounding the input to the
message center indicator and the warning will be displayed during the next ignition cycle of OFF to
RUN. This low oil level sensor is only monitored when the ignition switch is OFF.
There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the
oil pan and reach the correct level.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: ^
THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR
TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE
ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR
JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING
THE GROUND COULD CAUSE THE VEHICLE TO MOVE.
^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE
VEHICLE FROM FALLING.
^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND
FALLING OFF THE JACK.
Jacking Points - Front The front jacking point is a tab that extends from the lower control arm.
Jacking Points - Rear
1. The rear jacking points are located on the rear axle tube.
CAUTION: ^
Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
LIFTING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Vehicle Lifting > Component Information > Description and
Operation > Page 2844
Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE
REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED
INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF
THE VEHICLE DURING THESE OPERATIONS.
CAUTION: ^
Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2853
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2854
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2855
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2856
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2857
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2858
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2859
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2860
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2861
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2862
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance
Tires: Recalls Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2871
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2872
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2873
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2874
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2875
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2876
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2877
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 2883
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 2884
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns > Page 2885
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2891
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2892
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2893
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment >
Page 2898
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
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> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2903
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2904
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2905
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2906
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2907
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2908
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2909
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2910
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2911
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
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Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 2912
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement
Technical Service Bulletin # 00L12 Date: 010101
Information
00L12
SPECIAL FIELD ACTION
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Original - January 2001
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1, February 5, 2001 - Updated Information
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Supplement # 2, February 19, 2001 - Updated Information
All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2917
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2918
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2919
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2920
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2921
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2922
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2923
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2924
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2925
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2926
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2927
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2928
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2929
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2930
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2931
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2932
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2933
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2934
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2935
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2936
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2937
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2938
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2939
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2940
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label
Non-Compliance
Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2949
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2950
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2951
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2952
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2953
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2954
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 2955
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2961
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2962
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 2963
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page
2968
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement
Technical Service Bulletin # 00L12 Date: 010101
Information
00L12
SPECIAL FIELD ACTION
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Original - January 2001
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1, February 5, 2001 - Updated Information
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Supplement # 2, February 19, 2001 - Updated Information
All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2973
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2974
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2975
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2976
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2977
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2978
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2979
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2980
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2981
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2982
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2983
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2984
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2985
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2986
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2987
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2988
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2989
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2990
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2991
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2992
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2993
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2994
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2995
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 2996
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement Equipment > Page
3002
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3007
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3008
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3009
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3010
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3011
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3012
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3013
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3014
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3015
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 3016
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3021
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3022
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3023
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3024
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3025
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3026
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3027
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3028
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3029
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3030
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3031
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3032
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3033
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3034
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3035
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3036
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3037
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3038
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3039
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3040
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3041
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3042
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3043
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 3044
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label
Non-Compliance
Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3053
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3054
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3055
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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> All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3056
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3057
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3058
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 3059
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Page 3060
Tires: Specifications
Tire Tread Depth P225/70R15 A/S 0.37 in
P235/75R15 A/T 0.42 in
P255/70R16 A/T 0.42 in
Maximum Radial Runount Aluminum 0.040 in
Steel 0.040 in
Maximum Lateral Runout Aluminum 0.040 in
Steel 0.040 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Page 3061
Tires: Service and Repair
Removal
1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel
bearings.
Note: To avoid damage or scratching to the center cap, place facing up when removed.
Loosen the lug nuts. 1
Remove the center cap.
2 With the weight of the vehicle on the wheels, loosen the lug nuts.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick
panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
3. Raise and support the vehicle.
4. Remove the wheel and tire assembly.
1 Remove the lug nuts.
2 Remove the wheel and tire assembly, using a side-to-side rocking motion.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug
nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
Clean the wheel hub mounting, surface and wheel pilot.
2. Install the tire and wheel assembly.
1 Position the tire and wheel assembly.
2 Install the lug trots hand-tight, then lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins
> Page 3062
3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake
roughness, shudder and vibration.
Tighten the lug nuts in a star pattern using a torque wrench or torque sticks.
4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the center cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance
Wheels: Recalls Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 3076
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification
Label Non-Compliance
Wheels: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 3086
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 3087
Wheels: Specifications
Maximum Radial Runount Aluminum 0.045 in
Steel 0.045 in
Maximum Lateral Runout Aluminum 0.045 in
Steel 0.045 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 3088
Wheels: Description and Operation
WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same
vehicle except in emergencies. Vehicle handling can be seriously affected and can result in loss of
control.
Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and
including full-rated load capacity when inflated to recommended inflation pressures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Wheel and Tire
Wheels: Service and Repair Wheel and Tire
Removal
1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel
bearings.
Note: To avoid damage or scratching to the center cap, place facing up when removed.
Loosen the lug nuts. 1
Remove the center cap.
2 With the weight of the vehicle on the wheels, loosen the lug nuts.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick
panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
3. Raise and support the vehicle.
4. Remove the wheel and tire assembly.
1 Remove the lug nuts.
2 Remove the wheel and tire assembly, using a side-to-side rocking motion.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug
nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
Clean the wheel hub mounting, surface and wheel pilot.
2. Install the tire and wheel assembly.
1 Position the tire and wheel assembly.
2 Install the lug trots hand-tight, then lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Wheel and Tire > Page 3091
3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake
roughness, shudder and vibration.
Tighten the lug nuts in a star pattern using a torque wrench or torque sticks.
4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the center cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Wheel and Tire > Page 3092
Wheels: Service and Repair Wheel Leaks
1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
Wheel Bearing: Specifications
Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
Lubricate the lip of the new wheel bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Wheel Bearing Check
Wheel Bearing: Testing and Inspection Wheel Bearing Check
1. Raise and support the vehicle.
^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can
be the cause of a strain problem.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH
CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
2. Spin the tire by hand to check the wheel bearings for roughness.
NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow
free movement of the tire and wheel assembly.
3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Wheel Bearing Check > Page 3098
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Testing and
Inspection > Wheel Bearing Check > Page 3099
Wheel Bearing: Testing and Inspection Wheel Bearing Inspection
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise the vehicle until the tire is off the floor.
2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of
the following actions.
^ On 4x2 vehicles, adjust the front wheel bearings.
^ On 4x4 vehicles, install a new wheel hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Solid Rear Axle
Wheel Bearing: Service and Repair Solid Rear Axle
Special Tools
Special Tools
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Solid Rear Axle > Page 3102
Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and
Repair > Solid Rear Axle > Page 3103
Wheel Bearing: Service and Repair Independent Rear Suspension
Wheel Bearing
Removal And Installation
1. Remove the wheel knuckle.
2. CAUTION: Make sure that the press adapter outside diameter is slightly smaller than the hub
outside diameter or damage to the knuckle will
result.
Using a suitable press, remove the hub from the bearing.
- Discard the hub.
3. NOTE: The retainer ring is tapered and must be installed flat side down.
Remove the retainer ring.
- Discard the retainer ring.
4. Using a suitable press, remove the bearing from the wheel knuckle.
- Discard the bearing.
5. CAUTION: The hub and bearing cannot be reused after disassembly.
To install. reverse the removal Procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Wheel Hub Nut 157-213 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
Wheel Fastener: Specifications
Wheel Nuts 135 Nm (100 lb/ft)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front
Wheel Fastener: Service and Repair Front
Removal
1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Remove the brake disc
and hub.
4. Using a suitable press, remove the wheel stud from the brake disc and hub.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 3113
Wheel Fastener: Service and Repair Rear
Special Tool(s)
Special Service Tool(s)
Removal
CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange,
wheel bearing or hub bearing can result.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which
can result in shifting of the vehicle curing these operations.
Turn the air suspension service switch off, if so equipped.
2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Remove
the rear disc brake caliper, rear disc support bracket and brake disc if so equipped. Support the
rear disc brake caliper with safety wire.
5. Using the C-Frame and Clamp Assembly Tool, press the wheel stud from its seat and discard.
Installation
CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 3114
1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned
with those made by the original wheel stud.
2. Seat new wheel studs in axle flange.
- Place four flat washers over the outside end of the wheel stud.
- Thread a standard wheel nut with the flat side against the washers.
- Tighten the wheel nut until the wheel stud head seats against the back side of the flange.
3. Remove the wheel nut and flat washers. 4. Install the brake disc, rear disc support bracket the
rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle.
7. Turn the air suspension service switch on, if so equipped.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: ^
THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR
TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE
ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR
JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING
THE GROUND COULD CAUSE THE VEHICLE TO MOVE.
^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE
VEHICLE FROM FALLING.
^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND
FALLING OFF THE JACK.
Jacking Points - Front The front jacking point is a tab that extends from the lower control arm.
Jacking Points - Rear
1. The rear jacking points are located on the rear axle tube.
CAUTION: ^
Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
LIFTING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Maintenance > Vehicle Lifting > Component Information > Description and Operation > Page
3118
Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE
REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED
INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF
THE VEHICLE DURING THESE OPERATIONS.
CAUTION: ^
Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System
Variable Cam Timing System
Overview
The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine
speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the
exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the
combustion chamber. The residual gases cool the combustion chamber and are inert when mixed
with the incoming fresh charge of fuel and air. This results in better fuel economy and lower
Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas
Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature.
Variable Cam Timing
The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1)
on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT)
sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP)
sensor, Powertrain Control Module (PCM) (Figure 129).
1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature
(IAT) sensor, Engine Coolant
Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and
Crankshaft Position (CKP) sensor for determining the operating conditions of the engine.
2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are
met. The PCM disables the VCT system if
a fault is detected.
3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse
ring mounted on the exhaust camshaft.
Relative cam position is calculated by measuring the time between the rising edge of Profile
Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse.
4. The PCM continually calculates a cam position error value based on the difference between the
desired and actual position and a duty
cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit.
5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a
rotation motion from the helical mechanism in
the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve
to correct for cam position error.
Variable Cam Timing System
HARDWARE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3126
Variable Cam Timing (VCT) Solenoid Valve
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the
solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam
timing.
Variable Cam Timing Unit Assembly
Variable Cam Timing (VCT) Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3127
in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when
oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up
to 30 degrees.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3128
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit
Assembly
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum
overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The
camshaft is allowed to rotate up to 30 degrees.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Actuators and Solenoids - Engine > Variable Valve
Timing Solenoid > Component Information > Description and Operation
Variable Valve Timing Solenoid: Description and Operation
VARIABLE CAM TIMING (VCT) SOLENOID VALVE
Variable Cam Timing (VCT) Solenoid Valve
The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system.
The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the
PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or
retard the cam timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading. For additional information, refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 3135
Compression Check: Testing and Inspection
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE
5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top
of the pistons in the low-reading cylinders. Repeat the compression pressure check on these
cylinders.
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 3136
2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent
cylinders indicate low compression pressures and squirting oil on each piston does not increase
compression, the head gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing
> Component Information > Specifications
Camshaft Bearing: Specifications
Camshaft Bearing Cap Bolts Stage 1 6 Nm
Stage 2 16 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing
> Component Information > Specifications > Page 3141
Camshaft Bearing: Service and Repair
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket
Camshaft Gear/Sprocket: Specifications
Camshaft sprocket bolt 63 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications > Camshaft Gear/Sprocket > Page 3146
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt 63 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Specifications
Camshaft: Specifications
Intake Lobe Lift 0.259 in
End Play 0.0003 - 0.007 in
Exhaust Lobe Lift 0.259 in
Maximum Allowable Lobe Lift Loss 0.005 in
Journal to Bearing Clearance 0.002 - 0.004 in
Journal to Bearing Clearance Service Limit 0.006 in
Journal Diameter 1.100 - 1.104 in
Bearing Inside Diameter 1.102 - 1.104 in
Maximum Camshaft Journal Runout 0.002 in
Hydraulic camshaft tensioner, RH 49 ft.lb
Hydraulic camshaft tensioner, LH 49 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > LH
Camshaft: Service and Repair LH
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Removal
1. Remove the camshaft roller followers. 2. Remove the LH hydraulic camshaft tensioner.
3. Remove the bolt and the camshaft sprocket.
4. Note: Mark the position of the camshaft bearing caps so they can be installed in the original
position.
Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply
tube.
5. Remove the camshaft.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > LH > Page 3152
1. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or
equivalent meeting Ford specification WSS-M2C153-G
before installing.
Install the camshaft.
2. Note: The camshaft bearing caps must be installed in the original position.
Note: After installing the bolts, check the camshaft for free rotation.
Position the oil supply tube, the camshaft bearing caps, and the bolts. -
Tighten in the sequence shown in two stages.
- Stage 1: Tighten to 6 Nm (53 inch lbs.).
- Stage 2: Tighten to 16 Nm (12 ft. lbs.).
3. The camshaft must be re-timed. 4. Install the camshaft roller followers.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > LH > Page 3153
Camshaft: Service and Repair RH
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Special Tools
Removal
1. Remove the camshaft roller followers. 2. Remove the RH hydraulic camshaft tensioner.
3. CAUTION: The right-hand camshaft sprocket bolt is a left-hand threaded bolt.
Using the special tool, remove the bolt and the camshaft sprocket.
4. Note: Mark the position of the camshaft bearing caps so they can be installed in the original
position.
Remove the bolts in the sequence shown and remove the camshaft bearing caps and the oil supply
tube.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine
> Component Information > Service and Repair > LH > Page 3154
5. Remove the camshaft.
Installation
1. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or
equivalent meeting Ford Specification WSS-M2C153-G
before installing.
Install the camshaft.
2. Note: The camshaft bearing caps must be installed in their original position.
Note: After installing the bolts, check the camshaft for free rotation.
Position the oil supply tube, the camshaft bearing caps, and the bolts. Tighten in the sequence shown in two stages:
- Stage 1: Tighten to 6 Nm (53 inch lbs.).
- Stage 2: Tighten to 16 Nm (12 ft. lbs.).
3. The camshaft must be re-timed. 4. Install the camshaft roller followers.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair
Lifter / Lash Adjuster: Service and Repair
Removal and Installation
l. Remove the camshaft roller followers.
2. Remove the hydraulic lash adjusters.
3. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or
equivalent meeting Ford specifications
WSS-M2C153-G prior to installing.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Special Tools
Removal
1. Remove the valve covers. 2. Remove the fuel supply manifold.
3. Note: Mark each camshaft roller follower to ensure its original position during reassembly.
Using the special tool, remove the camshaft roller followers.
4. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or
equivalent meeting Ford specification WSS-M2C153-G
prior to installing.
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System
Variable Cam Timing System
Overview
The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine
speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the
exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the
combustion chamber. The residual gases cool the combustion chamber and are inert when mixed
with the incoming fresh charge of fuel and air. This results in better fuel economy and lower
Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas
Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature.
Variable Cam Timing
The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1)
on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT)
sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP)
sensor, Powertrain Control Module (PCM) (Figure 129).
1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature
(IAT) sensor, Engine Coolant
Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and
Crankshaft Position (CKP) sensor for determining the operating conditions of the engine.
2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are
met. The PCM disables the VCT system if
a fault is detected.
3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse
ring mounted on the exhaust camshaft.
Relative cam position is calculated by measuring the time between the rising edge of Profile
Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse.
4. The PCM continually calculates a cam position error value based on the difference between the
desired and actual position and a duty
cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit.
5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a
rotation motion from the helical mechanism in
the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve
to correct for cam position error.
Variable Cam Timing System
HARDWARE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3165
Variable Cam Timing (VCT) Solenoid Valve
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the
solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam
timing.
Variable Cam Timing Unit Assembly
Variable Cam Timing (VCT) Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3166
in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when
oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up
to 30 degrees.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Variable Valve
Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System > Page 3167
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit
Assembly
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum
overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The
camshaft is allowed to rotate up to 30 degrees.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft >
Component Information > Specifications
Balance Shaft: Specifications
Balance shaft bolts 19 - 21 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain Guide
> Component Information > Specifications
Balance Shaft Chain Guide: Specifications
Balance shaft chain guide 80 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Chain
Tensioner > Component Information > Specifications
Balance Shaft Chain Tensioner: Specifications
Balance shaft tensioner bolts 21 - 22 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications
Connecting Rod Bearing: Specifications
Connectin Rod Bearing Clearance to Crankshaft - Desired 0.008-0.061 mm (0.0003-0.0024 in)
Clearance to Crankshaft - Allowable 0.013-0.048 mm (0.0005-0.002 in)
Bearing Wall Thickness 1.4-1.408 mm (0.0551-0.0554 in)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing >
Component Information > Specifications > Page 3181
Connecting Rod Bearing: Service and Repair
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Connecting Rod Bolt
Connecting Rod: Specifications Connecting Rod Bolt
Install the connecting rod cap in the original position.
Note: Do not exceed 20 Nm (15 ft. lbs.) when tightening the connecting rod nuts.
Install and tighten the connecting rod nuts until they touch the connecting surface of the connecting
rod cap.
Tighten the connecting rod nuts simultaneously in two stages:
- Stage 1: Tighten 20 Nm (15 ft. lbs.).
- Stage 2: Tighten 90 degrees.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Connecting Rod Bolt > Page 3186
Connecting Rod: Specifications
Connecting Rod Bearings Clearance to Crankshaft Desired 0.0003 - 0.0024 in
Clearance to Crankshaft Allowable 0.0005 - 0.002 in
Bearing Wall Thickness 0.0551 - 0.0554 in
Main Bearings Clearance to Crankshaft 0.0008 - 0.0015 in
Clearance to Crankshaft Allowable 0.0005 - 0.002 in
Bearing Wall Thickness 0.0709 - 0.0711 in
Rod Length Center to Center 5.746 - 5.749 in
Alignment (Bore-to-Bore Max. Diff.) Twist 0.0015 per 1.000 in
Alignment (Bore-to-Bore Max. Diff.) Bend 0.0049 per 1.000 in
Side Clearance (Assembled to Crankshaft) 0.0036-0.0106 in
Piston Pin Bore or Bushing I.D. 0.943-0.944 in
Rod Bearing Bore I.D. 2.237 in
Rod Bearing Bore Out-of-Round 0.0004 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine >
Component Information > Specifications > Page 3187
Connecting Rod: Service and Repair
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Coolant Drain Plug,
Cylinder Block > Component Information > Specifications
Coolant Drain Plug: Specifications
Engine block coolant drain plug 12 - 18 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications
Crankshaft Main Bearing: Specifications
Main Bearing - Clearance to Crankshaft 0.0008-0.0015 in
Main Bearing - Clearance to Crankshaft (Allowable) 0.0005-0.002 in
Bearing Wall Thickness 0.0709-0.0711 in
Main Bearing Cap Bolts 72 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing >
Component Information > Specifications > Page 3194
Crankshaft Main Bearing: Service and Repair
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Main Bearing Journal Diameter 2.243 - 2.244 in
Main Bearing Journal Runout Limit 0.002 in
Main Bearing Journal Taper Maximum Per Inch 0.0003 in
Connecting Rod Journal Maximum Out-of-Round 0.0003 in
Crankshaft Free End Play 0.002 - 0.0126 in
Main Bearing Journal Out-of-Round 0.0003 in
Main Bearing Journal Runout TIR Maximum 0.002 in
Main Bearing Journal Runout Service Limit 0.005 in
Main Bearing Thrust Face Runout TIR Maximum 0.010 in
Thrust Bearing Journal Length 1.039 - 1.041 in.
Main and Rod Bearing Journal Finish RMS Maximum 72 and 88
Main Bearing Thrust Face Finish RMS Maximum 20
Connecting Rod Journal Diameter 2.125 - 2.126 in
Connecting Rod Journal Taper Per Inch Maximum 0.0003 in
Main bearing cap bolts 72 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 3198
Crankshaft: Service and Repair
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Specifications
Engine Block Heater: Specifications
Block heater screw 14 - 16 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Specifications > Page 3202
Engine Block Heater: Service and Repair
Removal
1. Drain the cooling system. 2. Raise and support the vehicle.
3. Disconnect the connector.
4. Remove the block heater.
1 Note: Do not loosen the screw more than necessary for removal.
Loosen the screw.
2 Twist and slide the block heater to release the retainer clip and discard the retainer clip.
3 Remove the block heater.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications
Harmonic Balancer - Crankshaft Pulley: Specifications
Crankshaft Pulley Bolt Stage 1 44 ft.lb
Stage 2 Additional 90 degrees
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3206
Harmonic Balancer - Crankshaft Pulley: Service and Repair
Special Tools
Removal
1. Remove the fan shroud. 2. Remove the accessory drive belt.
3. CAUTION: This bolt is torque to yield and cannot he reused.
Remove the damper bolt.
4. Using the special tool, remove the crankshaft pulley.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 3207
1. Using the special tool, install the crankshaft pulley.
2. Install a new crankshaft pulley bolt.
- Tighten in two stages:
- Stage 1: Tighten to 60 Nm (44 ft. lbs.).
- Stage 2: Tighten 90 degrees.
3. Install the accessory drive belt. 4. Install the fan shroud.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Bore Clearance Selective Fit 0.0012 - 0.002 in
Diameter-Coded STD 3.952 - 3.528 in
Diameter-Coded 0.5 3.972 in
Diameter-Coded 1.0 3.990 - 3.991 in
Pin Bore Diameter (Red) 0.945 in
Pin Bore Diameter (Blue) 0.945 in
Top Ring Groove Width 0.0645 -0 0654 in
Bottom Ring Groove Width 0.075 - 0.0713 in
Oil Ring Groove Width 0.1378 - 0.1399 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications > Page 3211
Piston: Service and Repair
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Length 2.835 - 2.866 in
Diameter (Red) 0.9446 - 0.9447 in
Diameter (Blue) 0.9447 - 0.9449 in
To Piston Pin Bore Clearance 0.0004 - 0.0006 in
To Connecting Rod Bushing Clearance -0.0007 to -0.0017 in
Press Fit
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications > Page 3215
Piston Pin: Service and Repair
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Top Compression Ring Width 0.062 - 0.063 in
Bottom Compression Ring Width 0.068 - 0.069 in
Top Compression Side Clearance 0.002 - 0.003 in
Bottom Compression Side Clearance 0.002 - 0.003 in
Top Compression Ring 0.008 - 0.018 in
Bottom Compression Ring Gap 0.018 - 0.028 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications > Page 3219
Piston Ring: Service and Repair
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
The 4.0L Push Rod engine has hydraulic lifters and requires no valve clearance adjustments.
The 4.0L SOHC engine:
- Manufacturer does not indicate whether the type of valve arrangement for this engine.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions > Page 3227
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL SERVICE TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure.
NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service Precautions > Page 3228
Fuel Pressure Gauge
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Service and Repair
Rocker Arm Assembly: Service and Repair
Special Tools
Removal
1. Remove the valve covers. 2. Remove the fuel supply manifold.
3. Note: Mark each camshaft roller follower to ensure its original position during reassembly.
Using the special tool, remove the camshaft roller followers.
4. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or
equivalent meeting Ford specification WSS-M2C153-G
prior to installing.
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Specifications
Valve Cover: Specifications
Valve cover bolts 80 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH
Valve Cover: Service and Repair LH
Removal
CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply
manifold is used as a leverage device, damage may occur to the supply manifold. Care must be
taken when working around the fuel supply manifold.
1. Remove the upper intake manifold. 2. Disconnect the fuel line.
3. Disconnect the camshaft position (CMP) sensor electrical connector.
4. Disconnect the differential pressure feedback EGR transducer.
1 Disconnect the electrical connector.
2 Disconnect the vacuum hoses.
5. Disconnect the engine electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3237
6. Disconnect the electrical connector from the valve cover.
7. Disconnect the radio ignition interference capacitor electrical connector.
8. Disconnect the ignition coil electrical connector. 9. Disconnect the spark plug wires from the
ignition coil.
10. Remove the valve cover.
- Discard the gasket.
11. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component
Information > Service and Repair > LH > Page 3238
Valve Cover: Service and Repair RH
Removal and Installation
CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply
manifold is used as a leverage device, damage may occur to the supply manifold. Care must be
taken when working around the fuel supply manifold.
1. Remove the upper intake manifold. 2. Drain the engine cooling system.
3. Disconnect the upper radiator hose and tube.
1 Remove the bolt.
2 Release the hose clamp and position hose and tube aside.
4. Remove the heater hose bracket and disconnect the transmission dipstick tube. 5. Disconnect
the spark plug wires.
6. Remove the valve cover.
- Discard the gasket.
7. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications
Valve Seat: Specifications
Width Intake 0.06 - 0.094 in
Exhaust 0.05 - 0.083 in
Angle Degrees 45 deg
Runout TIR Maximum 0.002 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL
ON, DTC P0300 or P0301 Set
Valve Spring: Customer Interest Engine Control - MIL ON, DTC P0300 or P0301 Set
Article No. 02-3-2
02/18/02
^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC
TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES
EQUIPPED WITH 4.0L SOHC ENGINE ONLY
^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES
EQUIPPED WITH 4.0L SOHC ENGINE ONLY
FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC,
RANGER
MERCURY: 1997-2002 MOUNTAINEER
ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT
"ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set
when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due
to system interaction of higher than expected transient exhaust system backpressure (under heavy
acceleration) coupled with valve spring resonance points experienced at these engine speeds. This
interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher.
ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust
valve springs and replace with new service intake and exhaust valve springs. Refer to the following
Service Procedure for details.
SERVICE PROCEDURE
NOTE
THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR
WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S.
NOTE
PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT
VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > Customer Interest for Valve Spring: > 02-3-2 > Feb > 02 > Engine Control - MIL
ON, DTC P0300 or P0301 Set > Page 3250
1. Gain access to the valve springs.
2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with
new service intake and exhaust valve springs 2L2Z-6513-AA.
NOTE
ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER
TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS.
3. Road test vehicle to verify repair.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6513 42
OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine
Control - MIL ON, DTC P0300 or P0301 Set
Valve Spring: All Technical Service Bulletins Engine Control - MIL ON, DTC P0300 or P0301 Set
Article No. 02-3-2
02/18/02
^ DRIVEABILITY - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - DIAGNOSTIC
TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES EQUIPPED WITH
4.0L SOHC ENGINE ONLY
^ ELECTRICAL - LAMP - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES
EQUIPPED WITH 4.0L SOHC ENGINE ONLY
^ ENGINE - 4.0L SOHC - MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED DIAGNOSTIC TROUBLE CODES (DTC) P0300/P0301 STORED IN MEMORY - VEHICLES
EQUIPPED WITH 4.0L SOHC ENGINE ONLY
FORD: 1997-2002 EXPLORER SPORT, EXPLORER 2001-2002 EXPLORER SPORT TRAC,
RANGER
MERCURY: 1997-2002 MOUNTAINEER
ISSUE Some vehicles equipped with the 4.0L SOHC engine may exhibit a CHECK ENGINE LIGHT
"ON" with Diagnostic Trouble Codes (DTC) P0300 (Random Misfire) or P0301. The DTC will set
when the engine is operated at high RPM'S (4800 RPM and higher). The Misfire code results due
to system interaction of higher than expected transient exhaust system backpressure (under heavy
acceleration) coupled with valve spring resonance points experienced at these engine speeds. This
interaction may cause the' exhaust valve to hang open at engine speeds of 4800 RPM and higher.
ACTION Verify that the DTC sets only at 4800 RPM or higher. Remove current intake and exhaust
valve springs and replace with new service intake and exhaust valve springs. Refer to the following
Service Procedure for details.
SERVICE PROCEDURE
NOTE
THIS REPAIR ONLY APPLIES TO P0300/P0301 DTC'S SET ABOVE 4800 RPM. THIS REPAIR
WILL NOT CORRECT MISFIRE DTC'S SET AT LOWER RPM'S.
NOTE
PRIOR TO REPAIR, REFERENCE YOUR APPLICABLE WORKSHOP MANUAL FOR CORRECT
VALVE SPRING REMOVAL/REPLACEMENT PROCEDURES.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Spring: > 02-3-2 > Feb > 02 > Engine
Control - MIL ON, DTC P0300 or P0301 Set > Page 3256
1. Gain access to the valve springs.
2. Remove (quantity 12) existing intake and exhaust valve springs F77Z-6513-M and replace with
new service intake and exhaust valve springs 2L2Z-6513-AA.
NOTE
ALL "12" VALVE SPRINGS ("6" INTAKE AND "6" EXHAUST) MUST BE REPLACED IN ORDER
TO MAINTAIN/ENSURE PROPER VALVETRAIN DYNAMICS.
3. Road test vehicle to verify repair.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
6513 42
OASIS CODES: 499000, 608000, 609000, 6100000, 611000, 611500, 698298
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > Page 3257
Valve Spring: Specifications
Intake Valve Spring Compression Pressure at Specified Height 202.84 - 224.968 lbf at 1.413 1.445 in
Exhaust Valve Spring Compression Pressure at Specified Height 202.84 - 224.968 lbf at 1.413 1.445 in
Intake Valve Spring Free Length 1.7 in
Exhaust Valve Spring Free Length 1.7 in
Intake Valve Spring Assembled Height 1.569 - 1.601 in
Exhaust Valve Spring Assembled Height 1.569 - 1.601 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component
Information > Technical Service Bulletins > Page 3258
Valve Spring: Service and Repair
Special Tools
Removal and Installation
1. Remove the camshaft roller followers. 2. Position the piston at top dead center. 3. Hold the valve
in the cylinder head.
- Remove the spark plugs.
- Use a suitable tool to apply air pressure to the cylinder.
4. CAUTION: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the cylinder.
If air pressure must be removed, support the valve prior to removal.
Using the special tool, remove the valve spring retainer keys, the valve spring and the retainer.
5. Inspect the components.
6. Note: Lubricate the parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or
equivalent meeting Ford specification WSS-M2C153-G
prior to installing.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications
Valve: Specifications
Valve Stem Diameter Intake 0.274 - 0.275 in
Valve Stem Diameter Exhaust 0.274 in
Valve Stem to Guide Clearance Exhaust 0.001 - 0.003 in
Valve Stem to Guide Clearance Intake 0.001 - 0.002 in
Head Diameter Intake 1.807 - 1.815 in
Head Diameter Exhaust 1.531 - 1.539 in
Valve Face Angle Degrees 45 deg
Valve Face Runout Limit 0.001 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications > Page 3262
Valve: Service and Repair
Refer to Engine Service and Repair for "General Procedures" and "Disassembly and Assembly of
Subassemblies". See: Service and Repair
"General Procedures" typically covers cleaning and inspection of the following components as part
of engine overhaul:
- Crankshaft & Crankshaft Bearings
- Camshaft & Crankshaft Bearings
- Cylinder Head
- Valve train components (Valves, Seats, Springs, etc)
- Piston, Piston Pin, Connecting Rod
- Cylinder Block & Bore
"Disassembly and Assembly of Subassemblies" typically covers service of the following
components:
- Cylinder Head
- Piston, Piston Pin, & Connecting Rod Assemblies
Note that disassembly and assembly of the engine is covered under Engine Service and Repair. If
an internal engine component does not have a separate service procedure, the manufacturer did
not provide one. Please refer to Engine Service and Repair for available service procedures. See:
Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Locations > Page 3267
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Locations > Page 3268
Drive Belt: Description and Operation
The accessory drive system consists of the following: drive belt
- generator
- power steering pump
- A/C compressor
- water pump pulley
- drive belt tensioner
- belt idler pulley
- crankshaft pulley
The accessory drive: has a single serpentine drive belt (six ribs).
- has an automatic tensioner.
- is not adjustable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Drive Belt: Initial Inspection and Diagnostic Overview
1. Verify the customer's concern by operating the engine to duplicate the condition.
2. Inspect to determine if any of the following mechanical concerns apply: 3. Inspect for drive belt
cracking/chunking/wear. 4. If the concerns remain after inspection, determine the symptoms and go
to the symptom chart.
Under severe operating conditions (high temperature, low humidity), drive belt rib cracking can
occur at less than 96,000 km (60,000 miles). Drive belt rib cracking (cracks across grooves): is not a reason for concern.
- has no detrimental effect on drive belt performance.
Cracks parallel to grooves are acceptable. The drive belt is still perfectly functional until rib
chunking occurs. Drive belt chunking is where the rubber material actually chunks out between the
cracks. The drive belt should be replaced if chunking occurs.
V-Ribbed Belt With Cracks (Acceptable)
V-Ribbed Belt With Chunks Of Rib Missing (Not Acceptable)
5. If the concern(s) remains after inspection, determine the symptoms and go to the Symptom
Chart.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3271
Drive Belt: Symptom Related Diagnostic Procedures
1 of 2
2 of 2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3272
Drive Belt: Component Tests and General Diagnostics
Belt Tensioner
The automatic drive belt tensioner can be checked as follows: 1. With the engine running, observe
the drive belt tensioner movement. The drive belt tensioner should move (respond) when the A/C
clutch cycles
or when the engine is accelerated rapidly. If the drive belt tensioner movement is constant without
A/C clutch cycling or acceleration, a pulley or shaft is probably bent or a pulley is out of round. In
rare cases, excessive drive belt rideout (uneven depth of grooves in drive belt) can cause
excessive drive belt tensioner movement. This condition can he checked by installing the suspect
drive belt with a known good original equipment drive belt and repeating the observation.
Drive Belt Misalignment
CAUTION: Incorrect drive belt installation will cause excessive drive belt wear and may cause the
drive belt to come off the drive pulleys.
Note: Original equipment drive belts are made of a special cord construction and are subjected to
special testing before they are approved for use.
Non-standard new drive belts may track differently or incorrectly. If a new drive belt tracks
incorrectly, install a new original equipment drive belt to avoid performance failure or loss of drive
belt. With the engine running, check drive belt tracking (the position of the drive belt on one of the
grooveless pulleys, idlers or drive belt tensioner. If the edge of the drive belt rides beyond the edge
of the pulley, noise and premature wear may result). If a drive belt tracking condition exists, visually
check the drive belt tensioner for damage, especially the mounting pad surface. If the drive belt
tensioner is not installed correctly with the locating pins in the locating holes, the mounting surface
pad will be out of position. This will result in abnormal drive belt tension and chirp and squeal
noises. If the above procedures do not correct the drive belt noise, install a new drive belt.
However, the drive belt noise may return (with mileage) if one of the above conditions still exists
uncorrected. With engine running, visually observe the grooves in the pulleys (not the pulley flanges) for
excessive wobble. Install new components as required.
- Check all accessories, mounting brackets and drive belt tensioner, for any interference that would
prevent the component from mounting properly. Correct any interference condition and recheck
belt tracking.
- Tighten all accessories, mounting brackets and drive belt tensioner retaining hardware to
specification. Recheck drive belt tracking.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt > Component Information > Testing and Inspection > Page 3273
Drive Belt: Service and Repair
Removal and Installation
1. Remove the air cleaner outlet tube.
2. Remove the drive belt.
1 Rotate the drive belt tensioner counterclockwise.
2 Remove the drive belt.
3. Note: Refer to Component Locations for proper drive belt routing. See: Locations
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Specifications
Drive Belt Tensioner: Specifications
Drive belt tensioner bolt 30 - 40 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive
Belt Tensioner > Component Information > Specifications > Page 3277
Drive Belt Tensioner: Service and Repair
Removal and Installation
1. Remove the drive belt.
2. Remove the drive belt tensioner. 3. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Specifications
Engine Mount: Specifications
Lower engine mount bracket nuts 59 ft.lb
Upper engine mount bracket nuts 81 ft.lb
Lower engine mount bracket bolts 59 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount
Engine Mount: Service and Repair Engine Mount
Removal and Installation
1. Remove the fan shroud.
2. Remove the LH engine insulator nuts.
3. Remove the RH engine insulator nuts. 4. Raise and support the vehicle.
5. Remove the LH and RH engine support insulator nuts. 6. Raise and support the engine. 7.
Remove the engine support insulators. 8. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Engine Mount > Page 3283
Engine Mount: Service and Repair Powertrain/Drivetrain Mount Neutralizing
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH
CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
1. Raise and Support the vehicle. 2. Loosen, but do not remove, the powertrain/drivetrain mount
fasteners. 3. Lower the vehicle. 4. Move the vehicle in forward and reverse (2 - 4 ft).
CAUTION: Do not twist or strain the powertrain/drivetrain mounts.
5. Raise and support the vehicle. 6. Tighten the powertrain/drivetrain mount fasteners. 7. Lower the
vehicle. 8. Test the system for normal operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Specifications
Idler Pulley: Specifications
Belt idler pulley bolt 30 - 40 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler
Pulley > Component Information > Specifications > Page 3287
Idler Pulley: Service and Repair
Removal and Installation
1. Remove the drive bolt.
2. Remove the belt idler pulley. 3. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure at 2,000 rpm Hot 40-60 psi
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick
Tube > Component Information > Specifications
Engine Oil Dip Stick - Dip Stick Tube: Specifications
Oil level indicator tube bracket bolt 18 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Drain Plug >
Component Information > Specifications
Engine Oil Drain Plug: Specifications
Oil pan drain plug 19 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications
Technical Service Bulletin # 02-1-9 Date: 020121
Engine Oil - Oil Recommendations/Applications
Article No. 02-1-9
01/21/02
ENGINE - ENGINE OIL - RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30
MOTOR OILS - GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY
FORD: 1992-2002 CROWN VICTORIA 1993-1994 TEMPO 1993-1997 THUNDERBIRD 1993-2002
ESCORT, MUSTANG, TAURUS 1995-2000 CONTOUR 1998-2002 ESCORT ZX2 2000-2002
FOCUS 1993-1996 BRONCO 1993-1997 AEROSTAR 1993-2002 E SERIES, F-150, RANGER
1995-2002 WINDSTAR 1997-1999 F-250 LD 1997-2001 EXPLORER 1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES, SUPER DUTY F-53 STRIPPED CHAS. 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1991-2002 TOWN CAR 1993-1998 MARK VIII 1993-2002 CONTINENTAL 2000-2002
LS 1998-2002 NAVIGATOR
MERCURY: 1992-2002 GRAND MARQUIS 1993-1994 TOPAZ 1993-1997 COUGAR 1993-1999
TRACER 1993-2002 SABLE 1995-2000 MYSTIQUE 1999-2002 COUGAR 1997-2001
MOUNTAINEER
This article is being republished in its entirety to update the vehicle models, engines and years
affected.
NOTE
PLEASE REFER TO THE VEHICLE APPLICATION LIST LATER IN THIS TSB FOR A
COMPLETE LIST OF VEHICLES AFFECTED BY THIS TSB.
ISSUE Ford Motor Company now recommends SAE 5W-20 viscosity grade for servicing most
gasoline and flexible fueled vehicles.
ACTION All 2001 and 2002 vehicles where SAE 5W-20 is specified should be serviced at the
recommended oil change intervals using SAE 5W-20. This oil is an improved formulation to
improve fuel economy.
Testing has validated this viscosity grade can be used in many previous model year vehicles. It is
recommended ALL vehicles on the following Vehicle Application Listing be service with SAE
5W-20.
All 2001-2002 vehicles other than those listed in the "Exception 2001 Vehicles" or "Exception 2002
Vehicles" chart are being filled with SAE 5W-20
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3302
motor oil at the factory and should also be serviced with SAE 5W-20 oil.
Exception 2001 Vehicles
Exception 2002 Vehicles
NOTE
IF VEHICLE IS NOT LISTED IN THIS APPLICATION, SAE 5W-30 OIL IS RECOMMENDED.
REFER TO TSB 99-8-16.
Parts Block
OTHER APPLICABLE ARTICLES: 99-8-16 SUPERSEDES: 01-4-7 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 401000, 490000, 497000, 499000
Veh. App. Listing Approved For SAE 5W-20 Motor Oil
^ 1993-1996 1.9L Escort/Tracer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3303
^ 1995-2000 2.0L Zetec Contour/Mystique
^ 1999-2002 2.0L Cougar
^ 1997-2002 2.0L Escort/Tracer
^ 1998-2002 2.0L Escort ZX2
^ 2000-2002 2.0L Focus
^ 2001-2002 2.0L Escape
^ 1993-1997 2.3L Ranger
^ 1993-1994 2.3L Mustang
^ 1993-1994 2.3L Tempo/Topaz
^ 1998-2001 2.5L Ranger
^ 1995-2000 2.5L Contour/Mystique
^ 1999-2002 2.5L Cougar
^ 2001-2002 3.0L 4V Escape
^ 1996-2001 3.0L 4V Taurus/Sable
^ 1993-2002 3.0L (Vulcan) Aerostar/Ranger,
^ Taurus/Sable (Flexible Fuel and Gas)
^ 1995-2000 3.0L (Vulcan) Windstar
^ 1993-1994 3.0L (Vulcan) Tempo/Topaz
^ 2000-2002 3.0L 4V Lincoln LS
^ 1995-2002 3.8L Windstar
^ 1993-1997 3.8L Taurus/Sable,
^ Thunderbird/Cougar, Continental
^ 1994-2002 3.8L Mustang
^ 2002-2002 3.9L 4V Lincoln LS
^ 1997-2002 4.2L (SPI) F-150 (under 8500 GVW only), E-Series
^ 1996-2002 4.6L 2V Mustang
^ 1992-2002 4.6L Crown Victoria/Grand Marquis
^ 1991-2002 4.6L Town Car
^ 1994-1997 4.6L 2V Thunderbird/Cougar
^ 1996-2002 4.6L 4V Mustang Cobra
^ 1995-2002 4.6L 4V Continental
^ 1993-1998 4.6L 4V Mark VIII
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Technical Service Bulletins > Engine Oil - Oil Recommendations/Applications > Page 3304
^ 1997-2002 4.6L 2V Triton F-150/250 (under 8500 GVW only), E-Series, Expedition
^ 1993-1999 4.9L E-Series, F-Series
^ 1993-1995 5.0L Mustang/Mustang Cobra
^ 1993-1993 5.0L Thunderbird/Cougar
^ 1997-2001 5.0L Explorer/Mountaineer
^ 1993-1996 5.0L E-Series, F-Series, Bronco
^ 2000-2002 5.4L Excursion
^ 1998-2002 5.4L 2V/4V Navigator
^ 1997-2002 5.4L 2V F-1501250 (under 8500 GVW only), Expedition, E-Series, E-350
Chassis/RV/Cutaway
^ 1993-1997 5.8L F-Series, Bronco
^ 1993-1996 5.8L E-Series
^ 2000-2002 6.8L Excursion
^ 1997-2002 6.8L E-Series, E-350 Chassis/RV/Cutaway
^ 1999-2002 6.8L Super Duty F-Series 250 HD/350/450/550 Motorhome
^ 1993-1998 7.5L All Vehicles
NOTE
FOR 1993 THROUGH 1998 MODEL YEAR FFV USE XO-10W30-FFV.
NOTE
THE "EXCEPTION 2001-2002 VEHICLES" SHOULD BE SERVICED WITH SAE 5W-30 MOTOR
OIL
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter ............................................................................................................................................
............................................................. 4.7L (5.0 Qt)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 3307
Engine Oil: Fluid Type Specifications
Engine Oil Type ...................................................................................................................................
............................................... SAE 5W-30 Motor Oil
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component
Information > Specifications
Oil Filter Adapter: Specifications
Oil filter adapter bolt 42 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator >
Component Information > Description and Operation
Oil Level Warning Indicator: Description and Operation
This warning message is displayed when the engine oil level is low.
When the engine oil level is normal, the input to the message center indicator will be an open
circuit.
When the engine oil level is low, the low oil level sensor will close, grounding the input to the
message center indicator and the warning will be displayed during the next ignition cycle of OFF to
RUN. This low oil level sensor is only monitored when the ignition switch is OFF.
There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the
oil pan and reach the correct level.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Oil pan bolts 80 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Lower Oil Pan
Oil Pan: Service and Repair Lower Oil Pan
Oil Pan
Removal and Installation
1. Raise and support the vehicle.
2. Drain the engine oil.
3. Remove the bolts and the oil pan.
4. NOTE: All sealing surfaces must be cleaned prior to assembly. Use metal surface cleaner to
clean the sealing surfaces.
NOTE: Inspect integral oil pan gasket for cuts or damage that may cause leaks. Install a new
gasket if necessary.
NOTE: Fill the engine with clean engine oil.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component
Information > Locations > Page 3322
Oil Pressure Gauge: Testing and Inspection
Magnetic Gauge Testing
The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster
magnetic gauges.
To test the magnetic gauges:
^ Disconnect the connector from the appropriate sender and connect the signal wire to the
Instrument Gauge System Tester.
^ Turn the vehicle ignition switch lock cylinder to the ON position.
With Instrument Gauge System Tester attached to the oil pressure switch connector and the
ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System
Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark.
Short the connector directly to engine ground. The centerline of the pointer should fall slightly
above mid-scale.
^ If the oil pressure gauge tests within calibration, install a new oil pressure switch.
^ If the oil pressure gauge still tests out of calibration, install a new gauge.
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Specifications
Oil Pressure Sender: Specifications
Oil pressure sensor 9-11 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Specifications > Page 3326
Oil Pressure Sender: Description and Operation
The oil pressure switch is installed in the engine block and consists of a diaphragm and contact
points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil
pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Specifications > Page 3327
Oil Pressure Sender: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Additional information may also be found at Engine; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Specifications > Page 3328
Oil Pressure Sender: Service and Repair
Removal and Installation
1. Discard the battery ground cable.
2. Disconnect the oil pressure sensor electrical connector and remove the sensor.
3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or
Wsk-M2G350-A2.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Specifications
Oil Pick Up/Strainer: Specifications
Oil pump screen cover and tube bolts 8 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component
Information > Specifications > Page 3332
Oil Pick Up/Strainer: Service and Repair
Removal and Installation
1. Remove the oil pan.
2. Remove the oil pump screen cover and tube. 3. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Oil Pressure at 2,000 rpm Hot 40-60 psi
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications
Intake Manifold: Specifications
Lower Intake Manifold Bolts 13 ft.lb
Upper Intake manifold bolts 62 in.lb
Throttle Body bolts 62 in.lb
Fuel injection supply manifold bolts 18 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Lower
Intake Manifold: Service and Repair Lower
Removal and Installation
CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply
manifold is used as a leverage device, damage may occur to the supply manifold. Care must be
taken when working around the fuel supply manifold.
1. Remove the upper intake manifold.
2. Remove the lower intake manifold.
- Inspect the lower intake manifold gasket and install a new one if necessary.
3. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Lower > Page 3342
Intake Manifold: Service and Repair Upper
Removal and Installation
CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply
manifold is used as a leverage device, damage may occur to the supply manifold. Care must be
taken when working around the fuel supply manifold.
1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube.
3. Remove the accelerator cable snow shield.
4. Disconnect the accelerator cable and speed control (if equipped) actuator cable.
1 Pull up on speed control actuator cable to remove.
2 Rotate the throttle body cam and disconnect the accelerator cable from the cam.
5. Remove and position the accelerator cable and speed control (if equipped) actuator cables
aside.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Lower > Page 3343
6. Disconnect the RH upper intake manifold vacuum connection.
7. Disconnect the idle air control (IAC) valve electrical connector.
8. Disconnect the throttle position (TP) sensor electrical connector.
9. Disconnect the exhaust gas recirculation (EGR) vacuum regulator:
- Electrical connector
- Vacuum connector
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Lower > Page 3344
10. Disconnect the crankcase ventilation hose.
11. Disconnect the power brake booster vacuum hose.
12. Remove the eight bolts.
13. Note: Inspect and install new O-ring seals if necessary.
Disconnect the LH fuel vapor management valve (VMV) hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Lower > Page 3345
14. Note: Inspect and install new O-ring seals if necessary.
Disconnect the RH VMV hose.
15. Remove the upper intake manifold.
- Inspect upper intake manifold gasket and install a new one if necessary.
16. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning
Indicator > Component Information > Description and Operation
Oil Level Warning Indicator: Description and Operation
This warning message is displayed when the engine oil level is low.
When the engine oil level is normal, the input to the message center indicator will be an open
circuit.
When the engine oil level is low, the low oil level sensor will close, grounding the input to the
message center indicator and the warning will be displayed during the next ignition cycle of OFF to
RUN. This low oil level sensor is only monitored when the ignition switch is OFF.
There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the
oil pan and reach the correct level.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge >
Component Information > Locations > Page 3353
Oil Pressure Gauge: Testing and Inspection
Magnetic Gauge Testing
The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster
magnetic gauges.
To test the magnetic gauges:
^ Disconnect the connector from the appropriate sender and connect the signal wire to the
Instrument Gauge System Tester.
^ Turn the vehicle ignition switch lock cylinder to the ON position.
With Instrument Gauge System Tester attached to the oil pressure switch connector and the
ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System
Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark.
Short the connector directly to engine ground. The centerline of the pointer should fall slightly
above mid-scale.
^ If the oil pressure gauge tests within calibration, install a new oil pressure switch.
^ If the oil pressure gauge still tests out of calibration, install a new gauge.
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
Crankshaft Rear Seal
Special Tool(s)
Material
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3358
Removal
1. Remove the flexplate or flywheel. 2. Remove the crankshaft spacer plate. 3. Remove the
crankshaft spacer.
4. CAUTION: Avoid scratching or damaging the crankshaft rear seal running surface during
removal of the crankshaft rear seal.
Using the special tool, remove the crankshaft rear seal.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing
Seal > Component Information > Service and Repair > Page 3359
1. NOTE: Be sure the crankshaft rear sealing surface is clean and free of any rust or corrosion. To
clean the crankshaft rear seal surface area, use
extra-fine emery cloth or extra-fine 0000 steel wool with metal surface prep.
Lubricate the crankshaft rear seal with clean engine oil and install it on the special tool.
2. Install the special tools.
3. Position the crankshaft rear seal and the special tool.
4. Using the special tool, install the crankshaft rear seal. 5. Install the crankshaft spacer. 6. Install
the spacer plate. 7. Install the flexplate or flywheel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification
Cylinder Head Gasket: Technical Service Bulletins Engine - Reman Engine Head Gasket
Identification
TSB 06-18-16
09/18/06
IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN
REMANUFACTURED ENGINES - SERVICE TIP
FORD: 1999-2006 Mustang, Mustang, Mustang, Mustang, Mustang, Mustang 2000-2005
Thunderbird 2001-2005 Taurus 2001-2006 Crown Victoria, Crown Victoria 2005 Five Hundred,
Freestyle 1997-2005 Expedition 1997-2006 E-Series, Explorer, F-150, F-Super Duty 1999-2003
Windstar 1999-2004 F-53 Motorhome Chassis 2000-2005 Excursion 2001-2003 Explorer Sport
2001-2005 Escape, Escape, Explorer Sport Trac, Ranger 2004-2005 Freestar, Freestar 2006 F-53
Motorhome Chassis
LINCOLN: 2000-2006 Lincoln LS 2001-2002 Continental 2001-200 Town Car 1998-2004
Navigator, Navigator 2003-2004 Aviator 2006 Mark LT
MERCURY: 2001 Cougar 2001-2005 Sable 2001-2006 Grand Marquis 2003-2006 Marauder 2005
Montego 1997-2006 Mountaineer 2004-2005 Monterey 2005 Mariner
ISSUE On various vehicles when servicing the head gasket on certain Ford remanufactured
engines, it is critical to determine the type of remanufactured engine that is being serviced, in order
to identify the correct replacement gasket.
ACTION Follow the Service Procedure to help identify if the vehicle is equipped with a SID (for
originally equipment level thickness head gasket) or OVR (for oversized service level thicker head
gasket) remanufactured engine when replacing a head gasket.
SERVICE PROCEDURE
Use this TSB to help identify if the vehicle is equipped with a STD or OVR remanufactured engine
when replacing a head gasket. This will ensure that you obtain the proper head gasket (thicker for
OVR-oversized) for the engine you are repairing, as the engine may have milled engine block deck,
milled cylinder head deck, or an over sized bore in the cylinders. This information will be needed
when ordering parts. The parts catalogs already reflect the correct service numbers, as long as this
additional information is available.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3364
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3365
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3366
For certain remanufactured engines, the long block assembly will be uniquely identified with a build
date, reman code, service part number, and serial number. This metal tag will be marked with STD,
or with OVR (Figures 1-6).
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3367
Technical Service Bulletin # 02-1-4 Date: 020121
Engine Head Gasket - Approved Replacement Procedures
Article No. 02-1-4
01/21/02
ENGINE - APPROVED HEAD GASKET REPLACEMENT SERVICE PROCEDURES
FORD: 1992-1997 THUNDERBIRD 1992-2002 CROWN VICTORIA, ESCORT, MUSTANG,
TAURUS 1995-2000 CONTOUR 2000-2002 FOCUS 1995-2002 WINDSTAR 1997-2002 E
SERIES, EXPEDITION, EXPLORER, F-150 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION 2001-2002 ESCAPE
LINCOLN: 1992-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002 NAVIGATOR 2002
BLACKWOOD
MERCURY: 1992-1997 COUGAR 1992-1999 TRACER 1992-2002 GRAND MARQUIS, SABLE
1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER
ISSUE Some engine assemblies with aluminum cylinder heads repaired in-vehicle have been
found to leak coolant and/or oil from the cylinder head gasket area due to particle contamination or
scratches and dents at the head to block mating surfaces.
ACTION Refer to the following Service Information for recommended gasket sealing surface
preparation procedures. If the engine diagnosis points to a faulty head gasket (leaks oil, leaks
coolant, oil or coolant contamination, or air in coolant), thorough cleaning procedures are
necessary for a successful head gasket repair. Diagnosis and post-repair confirmation can be done
successfully utilizing leak detection methods such as a black light dye process.
SERVICE PROCEDURE
To sum up, a successful leak repair depends on:
^ Accurate diagnosis of the leak using Ford-recommended test equipment and procedures
^ Surface preparation and gasket installation using the approved tools, cleaners, and methods
^ Exercising CARE and CLEANLINESS during disassembly/assembly of components
^ Use of genuine Ford OEM replacement parts
^ Use of a Ford Remanufacturer
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 401000, 402000, 403000, 499000
Aluminum Cylinder Head - Removal From Engine
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3368
WARNING
ALUMINUM CYLINDER HEADS ARE HIGHLY POLISHED AND MUST BE HANDLED WITH
EXTREME CARE. AFTER REMOVING THE HEAD BOLTS, WITHDRAW THE HEAD FROM THE
ENGINE COMPARTMENT. USE EXTREME CARE NOTING THAT THE GASKET SURFACE OF
THE HEAD COULD BE DAMAGED ON THE WAY OUT OF THE VEHICLE IF ALLOWED TO HIT
AGAINST OTHER ENGINE COMPONENTS. ONCE REMOVED, PLACE THE HEAD ON A
BENCH, GASKET SIDE UP, USING A PIECE OF CLEAN CARDBOARD ON THE BENCH
SURFACE UNDERNEATH. DO NOT SLIDE THE HEAD GASKET SURFACE ALONG THE
BENCHTOP OR DAMAGE WILL OCCUR.
NOTE
SOME ENGINES REQUIRE A "DE-TORQUING" PROCEDURE OF THE CYLINDER HEAD
BOLTS. CONSULT WITH THE APPROPRIATE MODEL YEAR WORKSHOP MANUAL FIRST, AS
THIS PROCEDURE IS USUALLY DONE ON FOUR-VALVE ENGINES. HOWEVER, ALL
ALUMINUM HEADS ARE PRONE TO WARPAGE DURING REMOVAL IF TAKEN OFF WHEN
HOT OR WARM. THE ENGINE SHOULD BE COOLED SUFFICIENTLY BY THE TIME THE
HEADS ARE ACCESSIBLE DURING TEARDOWN. ALLOW AN ADEQUATE COOL DOWN
PERIOD.
NOTE
IN SOME ENGINE APPLICATIONS, IT MAY BE NECESSARY TO "RUBBER BAND" A FEW OF
THE HEAD BOLTS TOGETHER DUE TO TIGHT CLEARANCES OF THE HEAD NEAR
HEATER/AC PLENUMS AND THE BODY COWL. THIS WILL ALLOW THE BOLTS TO CLEAR
THE BLOCK DECK AS THE HEAD IS WITHDRAWN FROM THE VEHICLE.
Place CLEAN shop towels over the cylinder block bores to prevent further contamination from
reaching internal parts and surfaces. If a towel is to be removed, do it SLOWLY . Debris collected
on the towel can fall on the engine if care is not exercised as it is removed.
Gasket surfaces are machined to near-mirror surface quality. Scratches, dents, gouges, and other
impressions may allow oil, coolant, and compression gases to leak into other sealed cavities and/or
the atmosphere. Surface imperfections deteriorate the head gasket's ability to seal effectively.
Contamination on these surfaces will cause leaks from "shimming" the head even under full head
bolt torque. Contamination will also cause marks on the polished gasket surface, creating a leak
path.
Inspection For Damage and Cleaning Procedure
The overall straightness of the cylinder head and block face is held within very tight specification.
Defects known as "waviness" or "depressions" cannot be surface machined out with ordinary
equipment. Machining must meet manufacturer's specification on surface finish quality and be less
than 0.001" inch (0.025 mm) level as measured under a known quality straightedge using a feeler
gauge. If the engine has been overheated the cylinder head may have been damaged or warped.
Re-surfacing will not correct this damage.
The head must not contain any impressions on its sealing surface deeper than 0.001" (0.025 mm).
There must not be any scratches or gouges present, especially those which track to another
sealing cavity or to the atmosphere.
Ensure that the mating cylinder block surface is completely free of solid contamination, corrosion,
and fluids. Use Motorcraft Metal Surface Cleaner, F4AZ-19A536-RA or equivalent, to rid the
surface of any material, which could later interfere with the gasket's sealing ability.
WARNING
UNDER NO CIRCUMSTANCES ARE ANY ALUMINUM GASKET SURFACES TO BE CLEANED
USING RAZOR BLADES, ROTARY ABRASIVE DEVICES INCLUDING ROLOC AND 3M
BRANDED SCOTCHBRITE PRODUCTS, ROTARY WIRE BRUSHES, SINGLE HANDLED WIRE
BRUSHES, HAND ABRASIVE SUCH AS SANDPAPER OR EMERY CLOTH, OR ANY CARBON
STEEL BLADE. THESE TOOLS ARE PROVEN TO CUT AND DAMAGE ALUMINUM AND WILL
DISRUPT THE POLISHED FINISH. ABRASIVE PARTICLES ARE ALSO SUSCEPTIBLE TO
ENTERING THE ENGINE CAVITIES AND MAY CAUSE INTERNAL ENGINE DAMAGE. THE
ONLY TOOLS ACCEPTABLE ARE PLASTIC AND WOOD SCRAPERS COMBINED WITH USE
OF MOTORCRAFT METAL SURFACE CLEANER, F4AZ-19A536-RA, OR EQUIVALENT
SOLVENT.
The original head bolts are to be discarded. Only new head bolts are acceptable for use in a head
gasket repair. Use of old bolts can cause clamp load failure because they were stretched from the
last torquing procedure either from the plant or a previous field repair. The new head bolt shanks
and threads should be thoroughly cleaned, dried, and lightly lubricated. Oil the bolts and let oil drip
for a minimum of 5 minutes. Use of too much oil may cause hydraulic lockup in the bolt hole.
The corresponding bolt holes in the cylinder block must be free of contamination consisting of dirt
particles, coolant, and oil. Bolts can mechanically or hydraulically lock on top of these materials and
cause for poor clamping of the cylinder head gasket. Use very lightly compressed air to blow out
the bolt holes. Use care to prevent debris from scattering over the internal engine surfaces.
To clean the cylinder block gasket surface, a plastic or wood scraper in combination with Motorcraft
Metal Surface Cleaner, F4AZ-19A536-RA, or equivalent solvent can be used with a portable shop
vacuum. Move the scraper toward the vacuum nozzle to direct loosened material quickly away from
the block surface.
It is not necessary to expect aluminum head surfaces to be shiny and bright after the vehicle has
been in service. Sanding, scraping, or polishing will create surface depressions that cause leaks.
The surface is expected to be flat within 0.001" (0.025 mm) and free of dirt, metal chips, and liquid
contaminants. Any staining of the metal surface is considered normal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Cylinder Head Gasket >
Component Information > Technical Service Bulletins > Engine - Reman Engine Head Gasket Identification > Page 3369
Machining of aluminum heads and blocks is an unacceptable field practice for quality control
purposes of flatness and surface finish standards. Removing material will also raise the risk of
internal reciprocating components striking each other, as well as changing the emissions
calibration of the engine. Machining practices of aluminum blocks and heads are not reimbursable.
Ford Remanufacturers are authorized to perform this procedure and have the necessary
equipment to put the specified surface finish on the head within original factory limits.
Installation Onto the Cylinder Block Surface
WARNING
ANY GASKET SEALING AIDS WHICH ARE NOT LIMITED TO, AND INCLUDE AVIATION
CEMENT, COPPER SPRAYS, OR GLUES ARE NOT TO BE USED. THE GASKET MUST BE
FITTED DRY WITHOUT SUPPLEMENTAL SEALING AIDS. ATTEMPTS TO SEAL WITH THESE
COMPOUNDS WILL CAUSE HEAD SHIMMING AND/OR NEW LEAK PATHS. THESE
COMPOUNDS HAVE ALSO BEEN KNOWN TO CAUSE EMISSIONS SENSORS TO FAIL
THEREBY TRIPPING FAULT CODES IN THE PCM.
Ensure that all surfaces of the cylinder block, cylinder head, and gasket are fully free of any solid or
liquid contamination and have been prepared for assembly using Motorcraft Metal Surface Cleaner,
F4AZ-19A536-RA, or equivalent solvent. Also ensure that any residual dirt on the engine was
removed successfully from the surrounding areas of the block to head face of the head and the
block.
Using Workshop Manual procedures, assemble the head to the block carefully. Do not allow the
gasket surfaces to scrape or bang against other engine parts. The head may pick up material along
the way, if this is allowed. Once in place, with dowels properly aligned to the head and ensuring
that the head is fully square, seated, and resting on the block deck in a level condition, install new
"torque-to-yield" cylinder head bolts to a finger tight condition. Refer to the appropriate model year
Workshop Manual for the procedure to torque the head bolts in the correct sequence and at the
intervals specified. Failure to follow these instructions may result in a warped head, and damaged
head bolt threads.
Do not use "cheater pipes" on torque wrenches. Use a known quality, calibrated torque wrench.
Pull evenly and steady on each bolt. Do not exert side pressures on the bolt hex, which can disrupt
the integrity of the bolt head and give a false reading on the final torque value of the fastener.
Once the engine is fully reassembled, be sure that fluid levels have been topped off as required for
the operation. When the engine is ready for starting, ensure that the engine 6i1 pump is (was)
primed properly and is in a "ready to start" condition with all engine oil galleys having been charged
with oil.
WARNING
DO NOT RACE THE ENGINE UPON INITIAL STARTUP. MAINTAIN ENGINE IDLE TO BUILD OIL
PRESSURE. USE OF A MECHANICAL PRESSURE GAUGE WILL ENSURE THAT OIL FLOW
HAS DEVELOPED ON THE PUMP'S PRESSURE SIDE. A DEFECTIVE GAUGE OR LIGHT IN
THE INSTRUMENT PANEL WILL NOT VERIFY PRESSURE HAS BEEN OBTAINED. SEVERE
INTERNAL ENGINE DAMAGE WILL RESULT IF PRESSURE IS NOT OBSERVED AND
STEADILY MAINTAINED.
Allow a warm up period, which brings the engine to normal operating temperature. Check for leaks
around the gasket joints of the head, front cover, and associated component parts. The vehicle
should be road tested within normal guidelines to raise the engine to operating temperature and
verify the repair is sound.
Shut down the engine, allow for a cool-down and drain-back period to enable fluids to return to
levels. Check fluid levels using owner guide recommendations (dipstick, sight gages, etc.).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal >
Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
Special Tools
Removal
1. Remove the crankshaft pulley.
2. Using the special tool, remove the crankshaft front oil seal.
Installation
1. Note: Lubricate the seal lip with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or
equivalent meeting Ford specification
WSS-M2C153-G.
Using the special tools and install the crankshaft front oil seal.
2. Install the crankshaft pulley.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3381
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3382
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3383
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3384
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3385
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3386
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3387
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3388
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3389
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3390
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3391
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > Recalls for Intake Manifold Gasket: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3392
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3398
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3399
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3400
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3401
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3402
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3403
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3404
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3405
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3406
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3407
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3408
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intake Manifold Gasket: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3409
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
Special Tools
Removal
1. Remove the valve springs. 2. Remove the valve stem seals.
Installation
1. Note: Lubricate parts with Super Premium SAE 5W-30 Motor Oil XO-5W30-QSP or equivalent
meeting Ford specification WSS-M2C153-G
prior to installing.
Using the special tool, install the valve stem seals.
2. Install the valve springs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Specifications
Oil Pressure Sender: Specifications
Oil pressure sensor 9-11 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Specifications > Page 3417
Oil Pressure Sender: Description and Operation
The oil pressure switch is installed in the engine block and consists of a diaphragm and contact
points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil
pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Specifications > Page 3418
Oil Pressure Sender: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Additional information may also be found at Engine; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender
> Component Information > Specifications > Page 3419
Oil Pressure Sender: Service and Repair
Removal and Installation
1. Discard the battery ground cable.
2. Disconnect the oil pressure sensor electrical connector and remove the sensor.
3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or
Wsk-M2G350-A2.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft > Component
Information > Specifications
Balance Shaft: Specifications
Balance shaft bolts 19 - 21 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain Guide >
Component Information > Specifications
Balance Shaft Chain Guide: Specifications
Balance shaft chain guide 80 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Chain Tensioner
> Component Information > Specifications
Balance Shaft Chain Tensioner: Specifications
Balance shaft tensioner bolts 21 - 22 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications > Camshaft Gear/Sprocket
Camshaft Gear/Sprocket: Specifications
Camshaft sprocket bolt 63 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications > Camshaft Gear/Sprocket > Page 3434
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt 63 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3443
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3444
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3445
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3446
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3447
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3448
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3449
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3450
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3451
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3452
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3453
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > Recalls for Timing Chain: > 00M12 > Nov > 00 > Campaign - Camshaft Chain
Tensioner & Intake Gasket > Page 3454
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3460
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3461
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3462
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3463
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3464
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3465
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3466
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3467
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3468
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3469
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3470
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3471
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Guide >
Component Information > Specifications
Timing Chain Guide: Specifications
Jackshaft chain guide bolts 14 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3483
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3484
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3485
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3486
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3487
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3488
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3489
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3490
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3491
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3492
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3493
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Recalls for Timing Chain Tensioner: > 00M12 > Nov > 00 >
Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3494
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket
Technical Service Bulletin # 00M12 Date: 001101
Campaign - Camshaft Chain Tensioner & Intake Gasket
00M12
OWNER NOTIFICATION PROGRAM
Certain 1997 through 2000 Explorer/Mountaineer and 2001 Explorer Sport/Sport-Trac Vehicles
Equipped with 4.0L SOHC Engines - Camshaft Chain Tensioner and Lower Intake Manifold Gasket
Additional Coverage
^ Dealer Letter
^ Attachment I ^
Administrative Information
^ Refund Codes
^ Attachment II ^
Labor Allowances
^ Parts Ordering Information
^ Attachment III ^
Technical Information
^ Attachment IV ^
Questions & Answer Sheet
^ Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3500
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3501
Attachment I - Administrative Information
OASIS You must use OASIS to determine if a vehicle is eligible for this program.
NOTE:
When a claim is submitted on an "M" program the VIN number will remain in OASIS until the terms
of the program expire.
CLAIMS PREPARATION AND SUBMISSION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3502
^ Enter claims using DWE.
^ Refer to ACESII Manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company will only refund the cost of repairs for the camshaft chain tensioner and/or
lower intake manifold gaskets made before the date of the Owner Letter (or after the date of the
Owner Letter if an emergency repair was made away from the servicing dealer).
To qualify for the refund, the camshaft chain tensioner and/or lower intake manifold gasket must
have been the causal part for the repair. All supporting documentation must be retained in
accordance with the Warranty and Policy Manual.
Refer to ACESII Manual for Refund information. Enter claims using DWE:
Program Code: 00M12 Misc. Expense: REFUND Misc. Expense: ADMIN Misc. Expense: 0.2 Hr.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS
Parts Ordering Information
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below:
DOR/COR NUMBER DOR/COR for this program is 50196
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3503
DEALER PRICE For latest prices, check or call your:
^ DOES II
^ Updated Price Book
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW While performing this procedure the technician will install a:
^ New upper and lower intake manifold gaskets.
^ New cam chain tensioner and washer.
^ Volume reduction plug into the left cylinder head oil galley.
^ New oil galley plug.
IMPORTANT TIME SAVING REPAIR TIPS
^ Always use a hand impact driver with a short extension when loosening the oil galley plug. Be
sure the T-30 Torx(R) bit is in good condition, and that there is no foreign material inside the plug
which would prevent the bit from fully seating. The plug may be seized on some higher mileage
vehicles, and not seating the bit may cause the bit to damage the plug.
^ Before removing the engine coolant temperature sensor, relieve any residual cooling system
pressure by removing the radiator cap and then reinstalling it. Doing this will allow you to remove
the sensor without having to drain the cooling system.
^ During assembly, DO NOT use any silicone products as they may cause damage to the oxygen
sensors.
^ Allow the engine and cooling system to cool down prior to beginning this repair.
Question -- Are these procedures the same as related procedures found in TSBs or in the
Workshop Manual?
Answer -- No. If you follow the procedures in this set of instructions, you will not need to disconnect
the battery or install a memory saver, or drain and refill the cooling system. Also, this procedure
involves removal of the upper and lower intake manifolds to replace the gaskets. Once the
manifolds and the ECT are removed, the oil galley plug and the cam tensioner are easily accessed.
LOWER INTAKE MANIFOLD REMOVAL
1. Remove the accelerator control splash shield.
2. Disconnect the speed control and accelerator cables from the throttle body control lever and the
upper intake manifold.
3. Disconnect the intake air temperature (IAT) sensor.
4. Disconnect the fresh air tubes from the air cleaner outlet tube, then remove the air cleaner outlet
tube.
5. Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3504
6. Disconnect the following vacuum hoses: See Figures 1 and 2.
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
7. Remove the fasteners securing the EVR/VIS solenoid bracket. It is not necessary to disconnect
the solenoids. Refer to Figure 2.
8. Remove the upper intake manifold screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3505
9. Lift up the upper intake manifold to access the vapor management valve (VMV) hoses. Remove
the locking clips and disconnect the right and left VMV hoses. See Figure 3.
10. Remove the upper intake manifold by carefully sliding the manifold off of the exhaust gas
recirculation (EGR) tube. See Figure 3.
11. If equipped, position the engine vacuum reservoir aside. See Figure 4.
12. Remove the lower intake manifold. See Figure 4.
CAUTION:
The intake ports of the cylinder heads must be covered to avoid any foreign material from entering
the engine.
13. Clean all foreign material from the intake manifold/cylinder head area, then cover the cylinder
head ports with clean shop towels.
VOLUME REDUCTION PLUG AND CAM CHAIN TENSIONER REPLACEMENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3506
1. Disconnect the engine coolant temperature (ECT) sensor and the engine coolant temperature
sender. Position the wiring harness connectors away from the oil galley plug area. See Figure 5.
CAUTION:
Damage to the oil galley plug will occur if the Torx(R) bit is not fully seated. Use a hand impact
driver and an extension, striking the driver firmly, to loosen the plug.
2. Remove the oil galley plug. See Figure 5.
3. Install the volume reduction plug into the oil galley. See Figure 6.
CAUTION:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3507
The new oil galley plug comes pre-encapsulated with sealant. Do not apply additional sealant to
the plug.
4. Install the new oil galley plug. Tighten the plug until it is flush with the face of the cylinder head.
NOTE:
Failure to remove then reinstall the radiator cap may result in coolant draining when the engine
coolant temperature (ECT) sensor is removed.
5. Remove, then reinstall, the radiator cap.
6. Remove the ECT sensor only. See Figure 5.
7. Remove and discard the left cam chain tensioner and washer. See Figure 5.
8. Install the new cam chain tensioner and washer. Tighten the tensioner to 44 Nm (32 lb-ft). See
Figure 7.
9. Install and connect the ECT sensor. Tighten the sensor to 15 Nm (132 lb-in).
10. Connect the coolant temperature sender.
LOWER INTAKE MANIFOLD -- INSTALLATION
1. Remove the old gaskets from the lower intake manifold. Clean the manifold gasket mating
surfaces. Remove the shop towels from the cylinder heads and clean the gasket mating surfaces.
2. Install new lower intake manifold gaskets, making sure they are correctly seated.
3. Install the lower intake manifold. Tighten the bolts to 18 Nm (13 lb-ft).
4. Install the engine vacuum reservoir, if equipped.
5. Install the locking clips onto the right and left VMV hose connectors.
6. Install the new upper intake manifold gaskets.
CAUTION:
When installing the upper intake manifold, be sure that all vacuum lines are positioned back to
avoid pinching them under the manifold.
CAUTION:
DO Not use any silicone-based lubricants on the EGR tube 0-ring.
NOTE:
Using Penetrating and Lock Lubricant, E8AZ-19A501-B or equivalent non-silicone-based lubricant,
lightly lubricate the EGR tube 0-ring to allow
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3508
for easier installation of the upper intake manifold.
7. Position the upper intake manifold carefully, slide the manifold onto the EGR tube and connect
both right and left VMV hoses. Also, be sure to route the IAC valve connector into position.
8. Install the upper intake manifold screws. Tighten the screws to 7 Nm (62 lb-in).
9. Connect the IAC valve and TPS connector.
10. Install the EVR/VIS solenoid bracket. Tighten the screws to 3 Nm (26 lb-in).
11. Connect the following vacuum hoses:
^ Brake booster.
^ Intake manifold tuning valve (IMTV) servo, if equipped.
^ Right side upper intake vacuum supply (two hoses).
^ PCV valve.
12. Install the air cleaner outlet tube, and connect the fresh air tubes and IAT sensor.
13. Correctly route and secure the accelerator and speed control cables. Tighten the screws to 3
Nm (26 lb-in).
14. Install the accelerator control splash shield.
15. Start the engine and check for correct operation. Check and top off the cooling system as
needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3509
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3510
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Timing Chain Tensioner: > 00M12
> Nov > 00 > Campaign - Camshaft Chain Tensioner & Intake Gasket > Page 3511
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Technical Service Bulletins > Page 3512
Timing Chain Tensioner: Specifications
Jackshaft chain tensioner bolts 89 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > LH
Timing Chain Tensioner: Service and Repair LH
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Timing Drive Components-LH Hydraulic Chain Tensioner
Removal and Installation
1. Remove the upper intake manifold. 2. Remove the thermostat housing.
3. Remove the LH camshaft tensioner.
- If using a new washer, tighten to 44Nm (32lb-ft).
- If using the old washer, tighten to 67Nm (49 lb-ft).
4. Remove the pipe plug, and the oil volume reduction plug.
5. NOTE: Be sure to install the new oil volume reduction plug supplied with the hydraulic chain
tensioner.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain Tensioner >
Component Information > Service and Repair > LH > Page 3515
Timing Chain Tensioner: Service and Repair RH
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Removal and Installation
1. Remove the wheel and tire. 2. Remove the lower splash shield.
3. Remove the RH camshaft tensioner.
- If using a new washer, tighten to 44 Nm (32 lb-ft).
- If using the old washer, tighten to 67 Nm (49 lb-ft).
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Engine front cover bolts 14 ft.lb
Jackshaft thrust plate bolts 8 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3519
Timing Cover: Service and Repair
NOTE: Ford does not provide timing marks or additional information for servicing of the timing
chains/sprockets without the special tools listed in this procedure.
Removal
1. Drain the engine coolant. 2. Remove the crankshaft pulley.
3. Remove the accessory bracket and position aside.
4. Remove generator mounting bracket and position aside.
5. Disconnect the crankshaft position (CKP) sensor electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3520
6. Remove the water bypass hose.
7. Remove the lower heater water hose.
1 Squeeze the hose clamp.
2 Remove the hose.
8. Disconnect the lower radiator hose.
1 Squeeze the hose clamp.
2 Disconnect the hose.
9. On A/C equipped vehicles, remove the A/C line bracket and position aside.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3521
10. Remove the wiring harness retainer and position aside.
11. Note: The water pump is removed for clarity.
Remove the engine front cover.
Installation
1. Clean and inspect the sealing surfaces.
2. Install the engine front cover.
3. Install the wiring harness retainer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3522
4. On A/C equipped vehicles, install the A/C line bracket nut.
5. Connect the lower radiator hose.
1 Position the hose
2 Install the clamp.
6. Connect the lower heater water hose.
1 Position the hose.
2 Install the hose clamp.
7. Install the water bypass hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 3523
8. Connect the crankshaft position (CKP) sensor electrical connector.
9. Install the generator mounting bracket.
10. Install the accessory bracket. 11. Install the crankshaft pulley. 12. Raise and support the
vehicle.
13. Drain the engine oil. 14. Lower the vehicle. 15. Fill the engine with Super Premium SAE 5W-30
Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G. 16. Fill the
engine with coolant.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System
Variable Cam Timing System
Overview
The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine
speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the
exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the
combustion chamber. The residual gases cool the combustion chamber and are inert when mixed
with the incoming fresh charge of fuel and air. This results in better fuel economy and lower
Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas
Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature.
Variable Cam Timing
The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1)
on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT)
sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP)
sensor, Powertrain Control Module (PCM) (Figure 129).
1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature
(IAT) sensor, Engine Coolant
Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and
Crankshaft Position (CKP) sensor for determining the operating conditions of the engine.
2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are
met. The PCM disables the VCT system if
a fault is detected.
3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse
ring mounted on the exhaust camshaft.
Relative cam position is calculated by measuring the time between the rising edge of Profile
Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse.
4. The PCM continually calculates a cam position error value based on the difference between the
desired and actual position and a duty
cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit.
5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a
rotation motion from the helical mechanism in
the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve
to correct for cam position error.
Variable Cam Timing System
HARDWARE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System >
Page 3529
Variable Cam Timing (VCT) Solenoid Valve
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the
solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam
timing.
Variable Cam Timing Unit Assembly
Variable Cam Timing (VCT) Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System >
Page 3530
in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when
oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up
to 30 degrees.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Actuator > Component Information > Description and Operation > Variable Cam Timing System >
Page 3531
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit
Assembly
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum
overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The
camshaft is allowed to rotate up to 30 degrees.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Variable Valve Timing >
Variable Valve Timing Solenoid > Component Information > Description and Operation
Variable Valve Timing Solenoid: Description and Operation
VARIABLE CAM TIMING (VCT) SOLENOID VALVE
Variable Cam Timing (VCT) Solenoid Valve
The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system.
The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the
PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or
retard the cam timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Specifications
Fuel Pressure Test Port: Specifications
Fuel Pressure Relief Valve Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Technician Safety Information >
Page 3542
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3543
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Service Precautions > Page 3544
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel
supply line.
3. Remove the four bolts and the fuel supply line from the fuel supply manifold.
4. Remove the fuel supply line bracket bolt and the fuel supply line.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G, to aid installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > With 104 Pin Processor
Idle Speed: Specifications With 104 Pin Processor
Hot Idle ................................................................................................................................................
......................................................... 670 - 750 RPM
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > With 104 Pin Processor > Page 3549
Idle Speed: Specifications With 150 Pin Processor
With Automatic Transmission
Hot Idle ................................................................................................................................................
.................................................................. 750 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
.................................................................. 750 RPM
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Component Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service Precautions > Page 3557
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL SERVICE TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure.
NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter
> Fuel Pressure Release > System Information > Service Precautions > Page 3558
Fuel Pressure Gauge
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order: Specifications
Coil Terminal-To-Cylinder Relationship
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications > Page 3562
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions
Ignition Cable: Service Precautions
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions > Page 3570
Ignition Cable: Service and Repair
Spark Plug Wire Remover
SPECIAL SERVICE TOOL(S)
REMOVAL
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug.
2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the
ignition coil.
3. Remove the spark plug wires.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service Precautions > Page 3571
1. To install, reverse the removal procedure.
CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the
exhaust manifold.
NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or
equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug and ignition
coil boots of the spark plug wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Spark Plug Gap
Spark Plug: Specifications
Spark Plug Gap 1.3 - 1.4 mm
RH Original Spark Plug AGRF22PG
LH Original Spark Plug AGRF22P
New Spark Plug (Either Side) AGSF22PP
Spark Plugs 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Spark Plug Gap > Page 3576
Spark Plug: Specifications
Spark Plug Gap 1.3 - 1.4 mm
RH Original Spark Plug AGRF22PG
LH Original Spark Plug AGRF22P
New Spark Plug (Either Side) AGSF22PP
Spark Plugs 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3577
Spark Plug: Application and ID
RH Original Spark Plug Type ..............................................................................................................
.............................................................. AGRF22PG LH Original Spark Plug Type ............................
....................................................................................................................................................
AGRF22P New Spark Plug Type (Either Side) ...................................................................................
................................................................................. AGSF22PP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 3578
Spark Plug: Service and Repair
REMOVAL
1. Remove the spark plug wires. For additional information, refer to Ignition Cable.
2. Remove the spark plugs.
NOTE: ^
Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from.
New spark plugs can be used in any cylinder.
3. Inspect the spark plugs.
4. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading. For additional information, refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3582
Compression Check: Testing and Inspection
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE
5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top
of the pistons in the low-reading cylinders. Repeat the compression pressure check on these
cylinders.
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 3583
2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent
cylinders indicate low compression pressures and squirting oil on each piston does not increase
compression, the head gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
The 4.0L Push Rod engine has hydraulic lifters and requires no valve clearance adjustments.
The 4.0L SOHC engine:
- Manufacturer does not indicate whether the type of valve arrangement for this engine.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Water Pump
Water Pump: Specifications
Water pump bolts 6 - 9 ft.lb
Water pump stud bolts 6 - 9 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Water Pump > Page 3591
Water Pump: Specifications
Water pump pulley bolts 17 - 20 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 3592
Water Pump: Service and Repair
Removal
1. Remove the radiator.
2. Lift the accessory drive belt tensioner and remove the accessory drive belt.
3. Remove the belt idler pulley.
4. Slide the water bypass hose clamp back.
5. Disconnect the heater hose at the water pump.
1 Release the clamp.
2 Remove the hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 3593
6. Disconnect the lower radiator hose at the water pump.
1 Release the clamp.
2 Remove the hose.
7. Remove the water pump pulley.
8. Remove the water pump.
Installation
1. Note: Use Metal Surface Cleaner F4AZ-1DA536-RA or equivalent meeting Ford specification
WSE-M5B392-A and a suitable plastic or wooden
scraper to clean the scaling surfaces.
Install the water pump.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 3594
2. Connect the water bypass hose and position the clamp.
3. Install the water pump pulley.
4. Connect the lower radiator hose to the water pump.
1 Position the hose.
2 Install the clamp.
5. Connect the heater hose to the water pump.
1 Position the hose.
2 Install the clamp.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications
> Page 3595
6. Install the belt idler pulley.
7. Lift the accessory drive belt tensioner and install the drive belt. 8. Install the radiator.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Actuators and Solenoids - Cooling System >
Hydraulic Cooling Fan Solenoid Valve > Component Information > Description and Operation
Hydraulic Cooling Fan Solenoid Valve: Description and Operation
HYDRAULIC COOLING FAN DRIVE
Hydraulic Cooling Fan Pump With Integral Solenoid
The system consists of an engine-driven pump with an integral solenoid (Figure 50) on the pump
that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting
current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current
means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always
turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump.
It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the
high pressure lines. The cooler is similar to the power steering cooler (same purpose and function,
to keep the fluid cool).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Engine Coolant - Propylene Glycol Recommendations
Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations
Article No. 01-23-6
11/26/01
^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON
ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL
^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION
ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS
FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002
CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR
2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO
1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002
EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F
SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER
SPORT 2000-2002 F-650, F-750
LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII
2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD
MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE
1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002
VILLAGER 1997-2002 MOUNTAINEER
MERKUR: 1989 SCORPIO, XR4TI
This article is being republished in its entirety to update the model year coverage.
ISSUE This TSB article describes Ford Motor Company's position on the use of propylene
glycol-based engine coolants.
ACTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical
Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 3605
Ford Motor Company does not recommend nor endorse the use of engine coolants made with
propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene
glycol-based engine coolants.
Published information suggests that engine coolants made with propylene glycol may provide
engine cooling performance equivalent to engine coolants made with ethylene glycol. However,
different brands of engine coolant provide varying corrosion protection for the cooling system. Ford
does not have performance data for the multitude of engine coolants available in the aftermarket
and therefore cannot recommend the use of any coolant except those sold by Ford Customer
Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer
Service Division coolant for the vehicle.
Furthermore, claims of toxicological and environmental advantages of propylene glycol over
ethylene glycol may be misleading. When significant new information is developed, Ford will review
this policy.
Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene
glycol-based engine coolants. Those specifications do not refer to engine coolants made with
propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon
the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its
components, the cost of repairing the damage would not be covered by the Ford New Vehicle
Limited Warranty.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 402000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
Coolant Capacity 16.3 qt (US)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 3608
Coolant: Fluid Type Specifications
Antifreeze Type Ford Premium Engine Coolant (Green in color)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Drain Plug, Cylinder Block >
Component Information > Specifications
Coolant Drain Plug: Specifications
Engine block coolant drain plug 12 - 18 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Specifications
Coolant Reservoir: Specifications
Radiator Coolant Recovery Reservoir Bolts
....................................................................................................................................... 6-8 Nm
(53-71 in.lb.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Specifications > Page 3615
Coolant Reservoir: Service and Repair
Removal
1. Remove the air cleaner outlet tube and the engine air cleaner (ACL).
2. Remove the bolt and position the speed control servo aside.
3. Disconnect the windshield washer hose from under the dash panel and plug the end of the hose.
4. Disconnect the windshield washer pump electrical connector from the windshield washer
reservoir.
5. Position the (A) clamp back and disconnect the (B) radiator overflow hose from the (C) radiator
filler neck and plug the hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Specifications > Page 3616
6. Remove the (A) two nuts and the (B) bolts.
7. Remove the radiator coolant recovery reservoir and the windshield washer reservoir.
Installation
1. Install the radiator coolant recovery reservoir and the windshield washer reservoir.
2. Install the bolts and the two nuts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information >
Specifications > Page 3617
3. Connect the (B) radiator overflow hose to the (C) radiator filler neck and position the (A) clamp.
4. Connect the windshield washer pump electrical connector to the windshield washer reservoir.
5. Connect the windshield washer hose under the dash panel.
6. Position the speed control servo and bracket and install the bolt. 7. Fill the cooling system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade >
Component Information > Service and Repair
Fan Blade: Service and Repair
Removal and Installation
1. Remove fan shroud.
2. Remove the bolts.
3. Separate the fan blade from the fan clutch. 4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Specifications
Fan Clutch: Specifications
Fan clutch to water pump pulley nut 34 - 36 ft.lb
Fan blade to fan clutch bolts 14 - 19 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Clutch >
Component Information > Specifications > Page 3625
Fan Clutch: Tools and Equipment
Fan Clutch Holding Tool AST tool# 8005
Allows the technician to hold the water pump pulleuy in place while loosening the radiator fan.
2009 Suggested user price: $41.20
Assenmacher Specialty Tools 1 800 525 2943
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Hydraulic Cooling Fan
Solenoid Valve > Component Information > Description and Operation
Hydraulic Cooling Fan Solenoid Valve: Description and Operation
HYDRAULIC COOLING FAN DRIVE
Hydraulic Cooling Fan Pump With Integral Solenoid
The system consists of an engine-driven pump with an integral solenoid (Figure 50) on the pump
that is triggered by the powertrain control module (PCM). Fan speed is controlled by adjusting
current to the solenoid, which then changes the fluid flow to the hydraulic motor. More current
means the solenoid opens up, allowing higher pressure to increase the fan speed. The fan always
turns due to solenoid current leakage, even in cold engine cases. The motor is driven by the pump.
It contains a shaft on which the fan mounts. The motor also contains quick connect fittings for the
high pressure lines. The cooler is similar to the power steering cooler (same purpose and function,
to keep the fluid cool).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 15 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3633
Coolant Temperature Sensor/Switch (For Computer): Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3634
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3635
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Remove the thermostat and housing. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the Engine Coolant Temperature (ECT) sensor.
1 Disconnect the connector.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Engine Temperature Sensor > Component Information > Description and Operation > Cylinder Head Temperature Sensor
> Page 3640
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Engine coolant temperature (ECT) sensor 89 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch
> Temperature Sensor (Gauge) > Component Information > Specifications > Page 3644
Temperature Sensor (Gauge): Description and Operation
When the engine temperature is low, the resistance of the water temperature indicator sender unit
is high, thus restricting the flow of current through the gauge and moving the pointer only a short
distance. As the temperature of the coolant increases, the resistance decreases, allowing more
current to flow through the gauge and results in a corresponding movement of the pointer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications
Fan Shroud: Specifications
Fan shroud bolts 53 - 71 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3648
Fan Shroud: Service and Repair
Special Tools
Removal and Installation
1. Remove the air cleaner outlet tube.
2. Use the Fan Clutch Wrench and the Fan Hub Wrench to loosen and remove the fan blade.
3. Remove the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information >
Specifications > Page 3649
4. Lift the fan shroud out of the lower retaining clips.
5. Lift the fan shroud and the fan blade and clutch assembly together and remove from the vehicle.
6. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3658
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3659
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3665
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3666
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3667
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3668
Heater Core: Service Precautions
WARNING:
- CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY
TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE,
ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE
CLOSED AREA.
THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS
WORKING CORRECTLY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3669
Heater Core: Description and Operation
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3670
Heater Core: Testing and Inspection
WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS
NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS
A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES
OUTSIDE THE CLOSED AREA.
1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow
the heater core tube to the heater core and appear as a leak in the heater core.
NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good
and did not require installation of a new heater core. If a heater core leak is suspected, the heater
core must be tested by following the plugged heater core component test before the heater core
pressure test. Carry out a system inspection by checking the heater system thoroughly.
2. Check the integrity of the heater water hose clamps.
NOTE: Spring type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at the heater water hose connection and damage the
heater core.
Heater Core-Plugged
WARNING: THE HEATER CORE IN LET HOSE WILL BECOME TOO HOT TO HANDLE IF THE
SYSTEM IS WORKING CORRECTLY.
1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the
heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose
to see if it is hot.
If it is not hot. the heater core may have an air pocket
- the heater core may be plugged
- the thermostat is not working correctly.
Heater Core-Pressure Test Use Radiator/Heater Core Pressure Tester to carry out the pressure
test. 1. Drain the coolant from the cooling system. For additional information, refer to Cooling
system.
NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water
hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter
BT-7422-A from the radiator/heater core
pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter
with hose clamps.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the
adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure
into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the
pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater
water hoses do not leak, remove the
heater core from the vehicle and carry out the bench test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3671
Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant
from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and
adapter to the core tubes. Then connect the radiator/heater core pressure
tester to the adapter.
4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5.
If a leak is observed, install a new heater core.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3672
Heater Core: Service and Repair
Heater Core Removal and Installation Procedures
Removal
Note: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
1. Drain the radiator.
2. Remove the heater water hose.
1. Squeeze the clamps and pull the hoses off. 2. Disconnect the vacuum hose from the water
control valve.
3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument
Panel, Service and Repair, Removal and
Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair
4. Remove the A/C evaporator core housing. 5. Remove the powertrain control module (PCM).
6. Remove the PCM heat sink.
1. Remove the ground strap screw. 2. Remove the heat sink.
7. Remove the heater air plenum nuts from the engine side of the dash panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Technical Service Bulletins > Page 3673
8. Remove the heater core.
1. Remove the heater core cover to air plenum screws. 2. Lift off the cover.
9. Remove the heater core.
Installation
Note: Be sure to install a new oval foam seal around the heater core inlet and outlet tubes.
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3682
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3683
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3689
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core
Electrolysis/Leakage > Page 3690
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Page 3691
Heater Hose: Specifications
Heater hose bracket bolts 27 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Technical Service Bulletins > Page 3692
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Locations > Page 3697
Temperature Gauge: Testing and Inspection
Magnetic Gauge Testing
The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster
magnetic gauges.
To test the magnetic gauges:
^ Disconnect the connector from the appropriate sender and connect the signal wire to the
Instrument Gauge System Tester.
^ Turn the vehicle ignition switch lock cylinder to the ON position.
1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument
Gauge System Tester to water temperature indicator
sender unit C104, circuit 39 (RD/WH), and the other lead to ground.
2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine
coolant temperature gauge should indicate C (cold).
Key OFF.
3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge pointer should be in the one
quarter range to mid range. Key OFF.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Locations > Page 3698
4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge should indicate H (hot). Key
OFF.
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See:
Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument
Cluster/Pinpoint Tests
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation
Temperature Warning Lamp/Indicator: Description and Operation
This warning message is displayed when the engine coolant is overheating.
The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message
center indicator).
If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be
no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the
warning will be displayed.
The message center indicator filters this input; therefore, there will be a few seconds delay before
the warning is displayed or removed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component
Information > Specifications
Radiator Drain Plug: Specifications
Radiator Draincock ..............................................................................................................................
....................................... 2.0-2.7 Nm (18-25 in. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Specifications
Radiator Cap: Specifications
Pressure Test 13-18 psi
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 15 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3714
Coolant Temperature Sensor/Switch (For Computer): Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3715
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3716
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Remove the thermostat and housing. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the Engine Coolant Temperature (ECT) sensor.
1 Disconnect the connector.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature Sensor > Page 3721
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Engine coolant temperature (ECT) sensor 89 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications >
Page 3725
Temperature Sensor (Gauge): Description and Operation
When the engine temperature is low, the resistance of the water temperature indicator sender unit
is high, thus restricting the flow of current through the gauge and moving the pointer only a short
distance. As the temperature of the coolant increases, the resistance decreases, allowing more
current to flow through the gauge and results in a corresponding movement of the pointer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Locations > Page 3729
Temperature Gauge: Testing and Inspection
Magnetic Gauge Testing
The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster
magnetic gauges.
To test the magnetic gauges:
^ Disconnect the connector from the appropriate sender and connect the signal wire to the
Instrument Gauge System Tester.
^ Turn the vehicle ignition switch lock cylinder to the ON position.
1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument
Gauge System Tester to water temperature indicator
sender unit C104, circuit 39 (RD/WH), and the other lead to ground.
2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine
coolant temperature gauge should indicate C (cold).
Key OFF.
3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge pointer should be in the one
quarter range to mid range. Key OFF.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information
> Locations > Page 3730
4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge should indicate H (hot). Key
OFF.
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See:
Instrument Panel, Gauges and Warning Indicators/Testing and Inspection/Instrument
Cluster/Pinpoint Tests
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine
Cooling > Component Information > Description and Operation
Temperature Warning Lamp/Indicator: Description and Operation
This warning message is displayed when the engine coolant is overheating.
The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message
center indicator).
If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be
no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the
warning will be displayed.
The message center indicator filters this input; therefore, there will be a few seconds delay before
the warning is displayed or removed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
Thermostat Opening Temperature Starts to open 183-190 F
Fully open 210 F
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 3737
Thermostat: Description and Operation
THERMOSTAT HEATER CONTROL
Thermostat Assembly With Heater Control
The primary objective for the thermostat heater control is for improvement in fuel economy and
thermal efficiency. The system consists of a high temperature (98°C/208°F in lieu of a 90°C/194°F)
thermostat (Figure 51)that has a resistive heater within the wax element. The heater is controlled
by the PCM dependent on engine speed, throttle position, engine load, vehicle speed, air charge
temperature, transmission oil temperature and engine coolant temperature.
During low speed, low load and low air charge temperature conditions, the thermostat heater is
OFF and the engine is allowed to operate at an elevated coolant temperature. This should result in
lower internal friction and higher thermal efficiency, both leading to improved fuel economy.
During high speed, high load, high temperature conditions (air charge, transmission oil or engine
coolant), the PCM output is energized with a duty cycle to the thermostat heater. This heats the
wax and forces the thermostat to rapidly open wider allowing extra coolant to flow from the radiator.
This will reduce the coolant temperature and improve with performance demand.
It should be noted that the heater is only capable of supplying a SMALL amount of additional heat
to the wax element; it is NOT capable of opening the thermostat alone. The thermostat is 100%
duty cycle for short calibrated time and than the duty cycle is reduce to a maximum of 70% on and
30% off.
Approximately, unheated, the thermostat will begin to open at a coolant temperature of 98°C
(208°F) and will be fully open at 115°C (239°F). Energizing the heater will reduce the opening
temperature to about 80°C (176°F) and the fully open temperature to 110°C (230°F).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 3738
Thermostat: Service and Repair
Removal and Installation
1. Partially drain the cooling system. 2. Remove the upper radiator hose.
3. Remove the bolts, water outlet adapter and thermostat.
- Inspect the O-ring seal.
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Water Pump
Water Pump: Specifications
Water pump bolts 6 - 9 ft.lb
Water pump stud bolts 6 - 9 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Water Pump > Page 3743
Water Pump: Specifications
Water pump pulley bolts 17 - 20 ft.lb
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3744
Water Pump: Service and Repair
Removal
1. Remove the radiator.
2. Lift the accessory drive belt tensioner and remove the accessory drive belt.
3. Remove the belt idler pulley.
4. Slide the water bypass hose clamp back.
5. Disconnect the heater hose at the water pump.
1 Release the clamp.
2 Remove the hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3745
6. Disconnect the lower radiator hose at the water pump.
1 Release the clamp.
2 Remove the hose.
7. Remove the water pump pulley.
8. Remove the water pump.
Installation
1. Note: Use Metal Surface Cleaner F4AZ-1DA536-RA or equivalent meeting Ford specification
WSE-M5B392-A and a suitable plastic or wooden
scraper to clean the scaling surfaces.
Install the water pump.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3746
2. Connect the water bypass hose and position the clamp.
3. Install the water pump pulley.
4. Connect the lower radiator hose to the water pump.
1 Position the hose.
2 Install the clamp.
5. Connect the heater hose to the water pump.
1 Position the hose.
2 Install the clamp.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Page 3747
6. Install the belt idler pulley.
7. Lift the accessory drive belt tensioner and install the drive belt. 8. Install the radiator.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3753
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3754
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3755
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3756
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3757
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3758
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3759
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3760
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3761
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3762
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3763
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3764
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3765
4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3766
The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3767
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Technical Service Bulletins > Page 3768
Catalytic Converter: Specifications
Three-Way Catalytic Converter Bolts and Nut 25 - 34 ft.lb
Three-Way Catalytic Converter-to-Exhaust Manifold Bolts (4.0L SOHC) 27 - 37 ft.lb
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Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions
Catalytic Converter: Description and Operation Acronyms and Definitions
2V - L
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
2V: Two Valve engine configuration.
4V: Four Valve engine configuration.
ABS: Anti-lock Brake System.
A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by
cooling and dehydrating the air.
ACC: Air Conditioning Clutch. Indicates status of the A/C clutch.
ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch.
ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel.
ACP: Air Conditioning Head Pressure or A/C cycling switch input state.
ACPSW: Air Conditioning Pressure Switch.
ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module
(PCM) from the ACP switch or sensor.
ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout
control during heavy acceleration.
A/D: Analog-to-Digital. Analog-to-Digital signal conversion.
ADC: See ATDC.
AFCM: Alternative Fuel Control Module.
AIR: Secondary Air Injection.
AIRB: Secondary Air Injection Bypass.
Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system
when the electric air pump is commanded on.
AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System
has been evaluated for OBD (On-Board Diagnostic) II purposes.
Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry.
AIRM: Secondary AIR pump monitor.
Ambient Air Temperature: Temperature of the air surrounding an object.
Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits
of the signal.
ARB: Air Resource Board.
ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by
Speed Control Command Switch (SCCS) inputs.
ASCII: American Standard Code for Information Interchange.
ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke.
Measured in degrees of crankshaft rotation.
AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale,
rather than a digital display.
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> Description and Operation > Acronyms and Definitions > Page 3771
AWD: All-Wheel Drive.
BARO: Barometric Pressure.
Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC
solenoid disconnected.
Base Timing: Spark advance in degrees before top dead center of the base engine without any
control from the PCM or ICM.
Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected
directly to the battery. Compare "Vehicle Power (VPWR)."
BAT TEMP: Battery Temperature.
BJB: Battery Junction Box.
BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness.
BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be
hydraulic or electric.
BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the
Brake Pedal Position (BPP) switch.
BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by
applying voltage to the control line.
BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its
stroke. Measured in degrees of crankshaft rotation.
Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to
module and to the DLC.
CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of
pressurized intake air.
CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which
govern fuel economy standards.
CANVNT: Canister Vent Solenoid.
Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine
exhaust emissions.
CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency
Monitor has successfully completed.
CCM: Comprehensive Component Monitor.
CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various
EEC components.
CD A through J: Coil Driver 1 through 10.
Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM)
and safety inspections.
CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case.
CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade.
CHTIL: Cylinder Head Temperature Indicator Lamp.
CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor
thermistor.
CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor.
CKP: Crankshaft Position. Senses the position of the crankshaft.
CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return.
CL: Closed Loop. An operating condition or mode which enables operation based on sensor
feedback.
CMP: Camshaft Position. Indicates camshaft position.
CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault.
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> Description and Operation > Acronyms and Definitions > Page 3772
CMS: Catalyst Monitor Sensor. Downstream H025.
CMVSS: Canadian Motor Vehicle Safety Standards.
CNG: Compressed Natural Gas.
CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust
emissions.
CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of
fuel.
Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to
increase voltage.
Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the
temperature of external and internal components stabilize.
CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs
generated during Continuous Memory Self-Test.
Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM
whenever the vehicle is operating.
CPP: Clutch Pedal Position. Indicates clutch pedal position.
CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the
clutch pedal is depressed.
CQIS: Common Quality Indicator System.
CSE GND: Case Ground.
CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to
obtain the air/fuel mixture appropriate for closed throttle operation.
CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer.
Data Communications Link: A communication path between various in-vehicle electronic modules.
Accessed by scan tools through the Data Link Connector (DLC).
DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage
measurement of ON time versus the full cycle period, expressed in percent.
DCL: Data Communication Link.
DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a
distributor.
Digital: Controls process information by switching the current or voltage ON and OFF.
DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information.
DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above
the valves.
DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument
cluster.
DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure
transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator
Valve.
DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other
unwanted deposits.
DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while
the vehicle is operating.
DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system.
DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the
On-Board Diagnostic System.
DVOM: Digital Volt-Ohm Meter.
E-85: Fuel containing 85% ethanol alcohol.
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> Description and Operation > Acronyms and Definitions > Page 3773
EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an
electric air pump.
EAIRM: Electric Secondary Air Pump circuit Monitor.
ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade.
ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor
thermistor.
ECU: Electronic Control Unit. A module that handles the control strategy and monitors system
inputs or outputs.
EEC: Electronic Engine Control system.
EEC-V: Fifth generation EEC system.
EFT: Engine Fuel Temperature.
EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade.
EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor.
EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade.
EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor.
EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into
the combustion chamber.
EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the
monitor is complete.
EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to
operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control.
EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when
energized by the PCM.
EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is
threaded into the bottom of the intake plenum.
EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM.
EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the
EGR valve by varying the duty cycle to the regulator.
EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the
commanded output.
EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists
in the EGRV circuit.
EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module
(ICM) integrated into the PCM.
EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition
System.
EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System.
EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay
operation or noisy generator contacts.
EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new
vehicles perform to design specifications.
EPA: Environmental Protection Agency (U.S. Government).
EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that
requires the electronic storage of information.
ESOF: Electronic Shift-on-the-Fly.
EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere.
EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the
evaporative purge canister.
EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists
for the current commanded state.
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> Description and Operation > Acronyms and Definitions > Page 3774
EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system
canister from atmospheric pressure during the EVAP OBD II Monitor test.
Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal
which absorbs and holds fuel vapors.
EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap
Canister Purge Solenoid by the PCM.
EVO: Electronic Variable Orifice.
EWP: Electric Water Pump.
Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed
sensor.
FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays
OFF, LOW, or HIGH status.
FC: Fan Control.
FCS: Fuel Control Solenoid.
FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed.
FEAD: Front End Accessory Drive.
FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming
Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming.
FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that
displays the % alcohol content in fuel.
FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating
the inferred alcohol content of fuel.
FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is
reliable or not. Displays a YES or NO.
FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse
width.
FFV: Flexible Fuel Vehicle.
FIFO: First In First Out.
FILO: First In Last Out.
FIM: Fuel Indicator Module.
FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as
a percentage.
FLIV: Fuel Level Input Voltage.
FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle
function in the event of a PCM or EEC component failure.
FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2.
Fuel Pump (Modulated). Fuel pump duty cycle percentage.
FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump.
FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit.
FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults.
Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time.
FRP: Fuel Rail Pressure. Based on FRP V.
FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure
Sensor.
FSC: Fail-Safe Cooling.
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> Description and Operation > Acronyms and Definitions > Page 3775
FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or
prevents Natural Gas flow to the fuel rail.
FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or
NO.
FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit.
FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts.
FTP V: Fuel Tank Pressure Voltage. From the FTP transducer.
FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump.
FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update.
FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1
(HEGO1).
FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2
(HEGO2).
FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP.
Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and
pressure from the fuel tank into the Evaporative Emission Control System.
FWD: Front Wheel Drive.
GEM: Generic Electronic Module.
GEN: Generator.
GENF: Generator Output Fault.
GENFDC: Generator Field Control Output.
GFS: Generator field signal monitor.
GND: Ground.
GPM: Grams Per Mile. Also known as Gallons Per Minute.
GPS: Global Positioning Satellite.
Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with
California on-board diagnostics.
GSS: Gear Select Solenoid.
GVW: Gross Vehicle Weight.
Hall Effect: A process where current is passed through a small slice of semi-conductor material and
a magnetic field to produce a small voltage in the semi-conductor.
Hard Fault: A fault currently present in the system.
HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2.
High Compression.
HCF: Hydraulic Cooling Fan.
HCFD: Hydraulic Cooling Fan Drive.
HFC: Hydraulic Cooling Fan.
HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit.
HFP: High Fuel Pump.
HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output
commands with fixed values in response to internal
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> Description and Operation > Acronyms and Definitions > Page 3776
PCM malfunctions.
HO: High Output.
HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor.
Provides information on rich or lean exhaust conditions to the PCM.
Hot Soak: Period of time after an engine operates where localized combustion heat dissipates
throughout the engine.
HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the
HO2S sensor.
Hydrogen: Chemical symbol H. Highly flammable gas.
Hz: Hertz. Cycles per second.
IAC: Idle Air Control. Electrical control of throttle bypass air.
IAT: Intake Air Temperature.
IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor.
IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on
supercharged vehicles.
IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor.
IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit
functions.
ICM: Ignition Control Module. The module that controls the ignition system.
IFDM: Integrated Fuel Delivery Module.
IFS: Inertia Fuel Shutoff.
IGN GND: Ignition Ground.
Ignition: System used to provide high voltage spark for internal combustion engines.
IGNKEY(IGKY): Ignition Key status.
IGNSW (IGSW): Ignition Switch Position.
IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the
intake manifold.
IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults.
IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold.
INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output
from the PCM.
Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders.
Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion.
Intercooler: See CAC.
IPATS: Integrated Passive Anti-Theft System.
ISO: international Standards Organization.
KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even
when the vehicle is not operating.
KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM.
Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied
and the engine at rest.
Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the
engine running and the vehicle at rest.
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> Description and Operation > Acronyms and Definitions > Page 3777
KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position.
Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the
combustion chamber of an engine.
KOEC: Key On Engine Continuous.
KOEO: Key On Engine off.
KOER: Key On Engine Running.
KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.).
KPH: Kilometers Per Hour.
KS: Knock Sensor. Detects engine knock.
L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts.
LEV: Low Emissions Vehicle.
LFC: Low Fan Control.
LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps.
LIFO: Last In First Out.
LILO: Last In Last Out.
LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM.
LOOP: indicates OPEN or CLOSED loop status.
LPG: Liquefied Petroleum Gas.
LPLR: Low Pressure Low Resistance fuel injector.
M-V
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
M-85: Fuel containing 85% methanol alcohol.
MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine.
MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor.
MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold.
MFC: Medium Fan Control.
MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled.
MFP: Modulated Fuel Pump.
Microprocessor: A digital processor on a chip which perform arithmetic and control logic.
MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related
malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON."
MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the
crankshaft.
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> Description and Operation > Acronyms and Definitions > Page 3778
MON: Motor Octane Number.
Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter.
MSOF: Manual Shift-on-the-Fly.
MY: Model Year.
NA: Naturally Aspirated. Engine that is not supercharged or turbocharged.
NAAO: North American Automotive Operations.
NC: Normally Closed.
NG: Natural Gas. A system capable of using natural gas for vehicle operation.
NGS: New Generation STAR (Self-Test Automatic Readout) tester.
NGVM: Natural Gas Vehicle Module.
NO: Norm ally Open.
NO(x): Oxides of Nitrogen. Formed at high combustion temperatures.
NVH: Noise, Vibration, Harshness. A classification of vehicle concerns.
OASIS: On-Line Automotive Service Information System.
OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that
monitors PCM input and output control signals.
On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM.
OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO.
OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane.
OEM: Original Equipment Manufacturer.
OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the
valves.
OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp
ON when engine oil temperature exceeds safe limits.
Open Circuit: A circuit which does not provide a complete path for flow of current.
OL: Open Loop. An operating condition based on instructions not modified by PCM feedback.
O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen
content in exhaust gasses.
OSC: Output State Control.
OSS: Output Shaft Speed.
Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to
ultraviolet radiation.
Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines.
PATS: Passive Anti-Theft System.
PATSIL: Passive Anti-Theft System Indicator Light.
PATSIN: Passive Anti-Theft System Receive Signal.
PATSOUT: Passive Anti-Theft System Transmit Signal.
PATSTRT: Passive Anti-Theft System Starter Relay Control
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3779
PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control)
Processor.
PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase
vapors into the combustion chamber.
PF: Purge Flow. Amount of fuel vapor burned in the engine.
Photochemical: Term describing the action of light on air pollutants which results in creating smog.
PID: Parameter Identifier. Identifies an address in PCM memory which contains operating
information.
Powertrain: Engine and transmission/transaxle components.
Pressure - Absolute: A pressure referenced to a perfect vacuum.
Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude.
Sometimes called Barometric Pressure.
Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer.
Pressure - Differential: The pressure difference between two regions, such as between the intake
manifold and atmospheric pressure.
Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric
pressure.
PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization.
Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP
Sensor).
PPM: Parts Per Million. A measure used in emission analysis.
PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions.
Protocol: A set of rules for the exchange of information on a network.
PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed
information.
PSP: Power Steering Pressure. Indicates the pressure in the power steering system.
PSP V: Power Steering Pressure Input Voltage.
PTEC: Powertrain Electronic Controller.
PTO: Power Take-Off.
PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized.
PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle.
PWR GND: Power Ground. The main ground circuit in the EEC system.
Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and
Continuous Memory Self-Tests. Results are displayed as a series of DTCs.
RABS: Rear Antilock Brake System.
RAM: Random Access Memory. Memory into which information can be written as well as read.
REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate
at high temperatures.
Regulator: Controls the alternator/generator field current to maintain proper battery charge.
Contained within the PCM in smart charging applications.
Relay: An electromechanical device in which connections in one circuit are opened or closed by
changes in another circuit.
REM: Rear Electronic Module.
Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to
improve idle quality and improve emissions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3780
RF: Radio Frequency.
RFI: Radio Frequency Interference.
RFS: Returnless Fuel System.
RM: Relay Module. A module containing two or more relays.
ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered.
RON: Research Octane Number.
Routine: A group of related tasks, such as a series of diagnostic tests.
RPM: Revolutions Per Minute.
RS: Reverse Switch.
RTN: Return. A dedicated sensor ground circuit.
RWD: Rear Wheel Drive.
SAE: Society of Automotive Engineers.
SBS: Supercharger Bypass Solenoid or its signal output from the PCM.
SC: Supercharged or Supercharger.
SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from
the supercharger wastegate actuator to allow for maximum boost.
SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger
Bypass circuit.
SCICP: Supercharger Intercooler Pump Control.
SCICPF: Supercharger Intercooler Pump Control Fault.
SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump.
SCP: Standard Corporate Protocol.
Self- Test: See Quick Test.
Sensor: A device that detects the value or change in a physical quantity, such as temperature,
pressure or flow rate, and converts the data into an electrical signal.
SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is
individually energized and timed relative to its cylinder intake event.
Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic
Interference (EMI).
Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that
intended.
SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input
during closed-loop operation.
SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors.
SIL: Shift Indicator Lamp.
Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output
circuit.
SME: Society of Manufacturing Engineers.
SOF: Shift-On-the-Fly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3781
SOHC: Single Overhead Cam.
Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and
pulled to a central position.
ST: Scan Tool. A device that interfaces with and communicates information on a data link.
Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7
parts of air for every 1 part of fuel.
Switch: A device for making, breaking, or changing the connections in an electrical circuit.
TA: Traction Assist.
TACH: Tachometer.
TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has
an air bypass channel around the throttle plate.
TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel
slippage. 2. Turbocharger.
TDC: Top Dead Center.
Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration.
Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors.
Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees
before (BTDC) or after (ATDC) top dead center of the compression stroke.
TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to
measure intake air temperature.
TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate
information for the PCM.
TP V: Throttle Position Sensor Voltage.
Transducer: A device that receives energy from one medium and transfers it to another. For
example, thermal energy is converted to an electrical signal through a temperature probe.
Transmissions/Transaxles:
NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the
end.
TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns,
procedures, or general service information.
Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles
while running. Also used during engine crank.
Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure.
Variable Reluctance: A process of passing a varying magnetic field through wire windings and
inducing a voltage.
VCT: Variable Camshaft Timing.
VECI: Vehicle Emission Control Information label.
VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced.
Includes information about the year, model, engine, and plant origin of the vehicle.
VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister.
VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a
digital (DVOM) display.
VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare
"Battery Voltage
VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as
a reference by certain sensors.
WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain
other operating conditions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3782
Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger.
WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body.
Zip Tube: Another name for "fresh air duct" or "air inlet duct".
TRANSMISSIONS:
NOTE: The transmission naming convention is as follows:
^ The first character, a number, is the number of forward gears.
^ The second character, either the letter "F" or "R," represents front (transaxle) or rear
(transmission) wheel drive.
^ The next set of characters, a grouping of numbers, represents the design torque capacity of the
transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle).
^ The last character, if used, is one of the following:
^ "E" for electronic shift
^ "N" for non-synchronous shift
^
"S" for synchronous shift
^ "W" for wide ratio
^ 4F27E: Also known as the FN Focus automatic transmission.
^ 4F44E: Formerly known as the CD4E.
^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E.
^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E.
^ 4R44E: Formerly known as A4LD for 3.0L applications.
^ 4R55E: Formerly known as A4LD for 4.0L applications.
^ 4R70W: Formerly known as AOD-E.
^ 4R100: Formerly known as E4OD.
^ 5R44E: Formerly known as A5LD for 3.0L applications.
^ 5R55E: Formerly known as A5LD for 4.0L applications.
^ 5R55N: Lincoln LS automatic transmission.
^ 5R55W: Wide-ratio truck transmission.
^ 4x4L: 4x4 Low.
^ A/T: Automatic Transmission.
^ CCS: Coast Clutch Solenoid.
^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists.
^ EPC: Electronic Pressure Control.
^ EPCV: Electronic Pressure Control Volts.
^ ESS: Electronic Shift Scheduling.
^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E.
^ M5OD: Manual 5-Speed transmission with overdrive (RWD).
^ M/T: Manual Transmission/Transaxle.
^ NPS: Neutral Pressure Switch or its signal input to the PCM.
^ OCS: Overdrive Cancel Switch.
^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft.
^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear
Switch (NGS), and Transmission Switch Neutral (TSN).
^ REVERSE or REV: Transmission Reverse Switch Input.
^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual
transmission/transaxle vehicles.
^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission.
^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and
disengagement of the Torque Converter Clutch.
^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS)
has been activated.
^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled
transmissions.
^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between
an engine and transmission/transaxle.
^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid.
^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same
case. Front-wheel drive applications.
^ Transmission: A device which selectively increases or decreases the ratio of relative rotation
between its input and output shafts. Rear-wheel drive applications.
^ TR: Transmission Range. The range in which the transmission is operating.
^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to
the PCM on the transmission range selector position.
^ TR V: Transmission Range Voltage.
^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft.
^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is
proportional to vehicle speed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3783
Catalytic Converter: Description and Operation Catalyst Efficiency Monitor - Federal Test
Procedure
Catalyst Efficiency Monitor - Federal Test Procedure
The Catalyst Efficiency Monitor uses an oxygen sensor before and after the catalyst to infer the
hydrocarbon efficiency based on oxygen storage capacity of the catalyst. Under normal, close-loop
fuel conditions, high efficiency catalysts have significant oxygen storage. This makes the switching
frequency of the rear Heated Oxygen Sensor (HO2S) very slow and reduces the amplitude of those
switches as compared to the switching frequency and amplitude of the front HO2S. As the catalyst
efficiency deteriorates, its ability to store oxygen declines. The post-catalyst or downstream HO2S
signal begins to switch more rapidly with increasing amplitude, approaching the switching
frequency and amplitude of the pre-catalyst or upstream HO2S.
All applications utilize an FTP-based (Federal Test Procedure) catalyst monitor. This simply means
that the catalyst monitor must run during a standard FTP emission test as opposed to the
20-second steady state catalyst monitor used in 1994 through some 1996 vehicles. Two slightly
different versions of the catalyst monitor are used in the 2001 model year.
Switch Ratio Method (1996 - 2001)
1. In order to assess catalyst oxygen storage, the monitor counts front and rear HO2S switches
during part-throttle, close-loop fuel condition after
the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are
accumulated in up to nine different air mass regions or cells although three air mass regions is
typical. Rear switches are counted in a single cell for all air mass regions. When the required
number of front switches has accumulated in each cell, the total number of rear switches is divided
by the total number of front switches to compute a switch ratio. A switch ratio near 0.0 indicates
high oxygen storage capacity, hence high HC efficiency. A switch ratio near 1.0 indicates low
oxygen storage capacity, hence low HC efficiency. If the actual switch ratio exceeds a calibrated
threshold switch ratio, the catalyst is considered failed.
Inputs from Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) (warm
engine), IAT (not extreme ambient temperatures), Mass Air Flow (MAF) (greater than minimum
engine load), Vehicle Speed Sensor (VSS) (within vehicle speed widow) and Throttle Position (TP)
(at part-throttle) are required to enable the Catalyst Efficiency Monitor.
2. The DTCs associated with this test are Diagnostic Trouble Code (DTC) P0420 (Bank 1) and
P0430 (Bank 2). Because an Exponentially
Weight Moving Average algorithm is use for malfunction determination, up to six driving cycles may
be required to illuminate the Malfunction Indicator Lamp (MIL) during normal customer driving. If
Keep Alive Memory (KAM) is reset, a malfunction will illuminate the MIL in 2 drive cycles.
Index Ratio Method (some 2001 and beyond)
1. In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches
during part-throttle, closed-loop fuel conditions
after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are
accumulated in up to three different air mass regions or cells. While catalyst monitoring entry
conditions are being met, the front and rear HO2S signal lengths are continually being calculated.
When the required number of front switches has accumulated in each cell, the total signal length of
the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index
ratio. An index ratio near 0.0 indicates high oxygen storage capacity, hence high efficiency. A
switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual
index ratio exceeds the threshold index ratio, the catalyst is considered failed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3784
Inputs from ECT or CHT (warm engine), IAT (not extreme ambient temperatures), MAF (greater
than minimum engine load), VSS (within vehicle speed widow) and TP (at part-throttle) are required
to enable the Catalyst Efficiency Monitor.
2. The DTCs associated with this test are DTC P0420 (Bank 1) and P0430 (Bank 2). Because an
Exponentially Weighted Moving Average
algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate
the MIL during normal customer driving. If KAM is reset, a malfunction will illuminate the MIL in 2
drive cycles.
If the catalyst monitor does not complete during a particular driving cycle, the already accumulated
switch/signal data is retained in Keep Alive Memory and is used during the next driving cycle to
allow the catalyst monitor a better opportunity to complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3785
Catalytic Converter: Description and Operation Catalyst and Exhaust Systems
Catalyst and Exhaust System
Overview
The Catalytic Converter and Exhaust Systems (Figure 135) work together to control the release of
harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of
Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon
Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons
(HCs). CO, NO(x), and HCs are major air pollutants, and their emission into the atmosphere must
be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream
Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust
tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic
converter efficiency is monitored by the On Board Diagnostic (OBD II) system.
Generic Catalyst and Exhaust System
Catalytic Converter
A catalyst is a material that remains unchanged when it initiates and increases the speed of a
chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature.
The concentration of exhaust gas products released to the atmosphere must be controlled. The
catalytic converter assists in this task. It contains a catalyst in the form of a specially treated
honeycomb structure saturated with catalytically active precious metals. As the exhaust gases
come in contact with the catalyst, they are changed into mostly harmless products. The catalyst
initiates and speeds up heat producing chemical reactions of the exhaust gas components so they
are used up as much as possible.
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the
catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe
before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO),
unburned Hydrocarbons (HCs) and Oxides of Nitrogen (NO) in the exhaust emissions to an
acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a
muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly,
the exhaust emissions are directed to the atmosphere through an exhaust tailpipe.
HARDWARE
The downstream HO2S may be located after the light off catalyst or underbody catalyst. The
underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be
common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the
catalyst and exhaust system, refer to Exhaust System.
Three Way Catalytic Converter
The Three Way Catalytic (TWC) converter contains either platinum (Pt) and Rhodium (Rh) or
Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of
unburned HCs and CO and the reduction reaction of NO. The three-way conversion can be best
accomplished by always operating the engine air fuel/ratio at or close to stoichiometry.
Exhaust Manifold/Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of
cylinders.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Acronyms and Definitions > Page 3786
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
Upstream Heated and Downstream Heated Oxygen Sensors
The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas.
In addition to providing the PCM with indications of how rich/lean the engine is operating, the
upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is
an input to the Catalyst Efficiency monitor.
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine, and it also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3787
Catalytic Converter: Testing and Inspection
For information regarding diagnosis of this system refer to Computers and Control Systems
Diagnosis.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3788
Catalytic Converter: Service and Repair
Removal
1. Remove the muffler assembly.
2. Disconnect the heated oxygen sensor (HO2S) connectors.
3. Remove the bolts.
4. Remove the bolts and nuts. 5. Remove the LH three way catalytic converter (TWC).
6. Remove the bolts. 7. Twist and remove the RH TWC.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information
> Description and Operation > Page 3789
Installation
1. Note: Before installing the TWCs, install new gaskets.
Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Specifications
Exhaust Manifold: Specifications
Exhaust manifold nuts 16 ft.lb
Exhaust manifold to exhaust pipe bolts 30 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > LH
Exhaust Manifold: Service and Repair LH
Removal and Installation
1. Raise and support the vehicle.
2. Remove the bolts. 3. Lower the vehicle.
4. Disconnect the hoses from the differential pressure feedback (EGR) transducer.
5. Disconnect the EGR valve to exhaust manifold tube from the exhaust manifold.
6. Disconnect the EGR valve to exhaust manifold tube from the EGR valve and remove the EGR
valve to exhaust manifold tube.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > LH > Page 3795
7. Remove the LH exhaust manifold.
8. Note: Use new exhaust manifold gaskets and nuts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information >
Service and Repair > LH > Page 3796
Exhaust Manifold: Service and Repair RH
Removal
1. Raise and support the vehicle.
2. Remove the bolts. 3. Lower the vehicle.
4. Remove the RH exhaust manifold.
5. Note: Use new exhaust manifold gaskets and nuts.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Service and Repair
Heat Shield: Service and Repair
1. Disconnect the battery cable. 2. Raise the vehicle.
3. Inspect the catalytic converter and muffler for loose or missing heat shields.
4. Install worm clamps for heat shields that are loose.
- Use one of the following clamps: FOTZ-5A231-A or W705949-S300.
- Trim off the excess ear of the worm clamp.
5. If the heat shields are missing, install new heat shields. If new heat shields are not available,
install a new catalytic converter. 6. Lower the vehicle. 7. Reconnect the battery cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Specifications
Muffler: Specifications
Muffler to Three-Way Catalytic Converter Bolts 22 - 36 ft.lb
Muffler to TWC Clamp Bolt 44 - 58 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Specifications > Page 3803
Muffler: Service and Repair
Removal
1. Remove the two bolts and loosen the clamp.
2. Disconnect the RH torsion bar link.
- Remove the nut and position the torsion bar link out of the way.
3. Pry the rear support slide out of the rubber insulator.
4. Pry the double support slides away from the insulators. 5. Remove the muffler. Slide the muffler
forward over the rear axle while twisting the muffler until the muffler is removed.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Specifications > Page 3804
1. Install the muffler over the rear axle and twist the muffler into position.
2. Note: Before installing the muffler into the rubber insulators, apply a soap solution to the support
slides.
Push the double support slides into the rubber insulators.
3. Push the rear support slide into the rubber insulator.
4. Position the RH torsion bar and install the nut.
5. Install the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Specifications > Page 3805
6. Tighten the clamp.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules
- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures
Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3813
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 3814
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3815
Powertrain Control Module: Specifications
PCM Connector 5 - 7 Nm
Powertrain Control Module Connector Bolt 7 Nm
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3816
Powertrain Control Module: Locations
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3817
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3818
Powertrain Control Module: Diagrams
Part (1 Of 3)
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3819
Part (2 Of 3)
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Technical Service Bulletins > Page 3820
Part (3 Of 3)
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Description and Operation > General Description and Operation
Powertrain Control Module: Description and Operation General Description and Operation
The PCM performs the following functions:
^ accepts input from various engine sensors to compute the required fuel flow rate necessary to
maintain a prescribed air/fuel ratio throughout the entire engine operational range.
^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel.
^ determines and compensates for the age of the vehicle and its uniqueness, also automatically
senses and compensates for changes in altitude.
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Description and Operation > General Description and Operation > Page 3823
Powertrain Control Module: Description and Operation Standard Models (Non BI-Fuel)
POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO)
The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem
generates vehicle speed information for distribution to the vehicle's electrical/electronic modules
and subsystems that require vehicle speed data. This subsystem senses the transmission output
shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired
signal or as a multiplexed data message.
The key features of the PCM-VSO system are to:
^ Infer vehicle movement from the output shaft sensor signal
^ Convert transmission output shaft rotational information to vehicle speed information
^ Compensate for tire size and axle ratio with a programmed calibration variable
^ Utilize a transfer case sensor for four wheel drive applications
^ Distribute vehicle speed information as a multiplexed message and/or an analog signal
The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft
Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is
sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per
mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into
the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing
changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information
can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM,
or by Speed and Odometer SCP multiplexed data messages.
The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT.
Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for
speed and distance data are transmitted as separate SCP messages over the SCP multiplex link.
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory
Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read
Only Memory
Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM
Description
Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an
Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the
vehicle strategy including calibration information specific to the vehicle and is capable of being
reprogrammed or reflashed repeatedly.
As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM as under Programming the VID Block for
a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block
not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can
also be tailored to accommodate various hardware changes made to the vehicle since production.
Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of
Acceptable Range. This is described under Making Changes to the VID Block and also under
Making Changes to the PCM Calibration. The VID block contains many items used by the strategy
for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane,
fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel
drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle
hardware and supported by the VID block will be displayed on the scan tool.
When changing items in the VID block, the strategy will place range limits on certain items such as
tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When
this limit is reached, the scan tool will display a message indicating the need to flash the PCM
again to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other
Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic
tool manufacturers users manual for details.
Programming the VID Block for a Replacement PCM
A new PCM will contain the latest strategy and calibration level for a particular vehicle. However,
the VID block will be blank and will need programming. There are two procedures available. The
first is an automatic data transfer from the old PCM to the new PCM and the second is manual data
entry into the new PCM.
Automatic data transfer will be performed if the old PCM is capable of communicating. This is done
by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The
stored data can now be downloaded to the new PCM after it has been replaced.
Manual data entry must be performed if the old module is damaged and is incapable of
communicating. Remove and replace the old PCM. You may be instructed to contact the "AS
BUILT" data center for the information needed to manually update the VID block with the scan tool.
Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M
technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed
World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or
"Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool.
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- Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Service and Repair > Flash Electrically Eraseable Programmable Read Only Memory > Page 3826
Powertrain Control Module: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Powertrain Control Module (PCM) electrical connector.
3. Remove the nuts and the PCM cover.
4. Remove the PCM.
INSTALLATION
1. To install, reverse the removal procedure.
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- Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Powertrain Control Module Power Relay: Locations
Part (1 Of 2)
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- Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3830
Part (2 Of 2)
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- Computers and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3831
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Emission Control Systems > Air Injection Pump Relay > Component Information > Description and Operation
Air Injection Pump Relay: Description and Operation
SOLID STATE RELAY
Solid State Relay
The solid state relay (Figure 124) switches the high current required for operation of the electric
AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM).
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Part (1 Of 2)
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3840
Part (2 Of 2)
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Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3841
Fuel Pump Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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- Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Powertrain Control Module Power Relay: Locations
Part (1 Of 2)
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- Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3845
Part (2 Of 2)
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- Fuel Delivery and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations > Page 3846
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and
Operation
Absolute Pressure Sensor: Description and Operation
THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR
Thermal Manifold Absolute Pressure (TMAP) Sensor
The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold
Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is
currently not being used. The MAP part of the sensor measures intake manifold air absolute
pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air
Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP)
sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced
into the intake manifold.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Specifications
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Nuts And Bolts 10 Nm
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Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Specifications > Page 3855
Mass Air Flow Sensor: Locations
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Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Specifications > Page 3856
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Switches - Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information
> Specifications > Page 3857
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
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> Specifications > Page 3858
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Loosen the air cleaner outlet tube clamp and position aside.
4. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor, Stud Bolt 19 Nm
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
3862
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
3863
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
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Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
3864
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the CMP sensor electrical connector.
2 Remove the CMP sensor stud bolt.
3 Remove the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 3868
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION SWITCH
Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches
The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch
pedal position and, in some manual transmission applications, both the clutch pedal engagement
position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference
Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP
signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed,
indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output
voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1
volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or
PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the
clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP
switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the
5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load
information in mass air flow and fuel calculations.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 15 Nm
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Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 3872
Coolant Temperature Sensor/Switch (For Computer): Locations
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Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Remove the thermostat and housing. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the Engine Coolant Temperature (ECT) sensor.
1 Disconnect the connector.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolts 10 Nm
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Page 3878
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Crankshaft Position Sensor: Description and Operation Electronic Engine Controls
The CKP sensor:
^ sends the PCM a signal indicating crankshaft position.
^ is essential for calculating spark timing.
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Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel)
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Crankshaft Position Sensor: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Crankshaft Position (CKP) sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor
has wear tabs that will wear off after several engine revolutions.
^ Be sure sensor wiring is routed away from the battery cable.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and
Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
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Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
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Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation
Fuel Level Sensor: Description and Operation
The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the
action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is
high, the resistance is high.
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3894
Fuel Tank Pressure Sensor: Service Precautions
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
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3895
Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure Sensor
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor
(Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles
equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank
pressure by forcing the system to purge.
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3896
Fuel Tank Pressure Sensor: Service and Repair
REMOVAL
1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction.
2. Remove the fuel tank pressure sensor.
1 Disconnect the electrical connector.
2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the
fuel tank.
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test the evaporative emission system. For additional information, refer to Evaporative
Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection/Component Tests and General Diagnostics/Component
Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emissions repair verification drive cycle. For additional information,
refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control
Systems/Evaporative Emissions System/Service and Repair
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Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and
Operation
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE SENSOR
Intake Air Temperature (IAT)
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals
The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type
(Figure 37), are thermistor devices in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
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Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel spark and MAF.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above.
However, one is located before the supercharger at the air cleaner for standard OBD II/cold
weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control border-line spark and to help determine intercooler
efficiency.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Bolt 25 Nm
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3904
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Switches - Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 3905
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Knock Sensor: Service and Repair
REMOVAL
1. Remove the lower in take manifold. For additional information, refer to Engine.
2. Remove the knock sensor.
1 Remove the bolt.
2 Remove the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3911
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3912
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3913
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3918
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3919
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 3920
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Heated Oxygen Sensor: Specifications
Heated Oxygen Sensor 41 Nm
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Locations > Oxygen Sensor Bank Locations
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Locations > Oxygen Sensor Bank Locations > Page 3929
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Diagrams > Diagram Information and Instructions
Heated Oxygen Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Heated Oxygen Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3944
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3945
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3946
Heated Oxygen Sensor: Connector Views
Ford does not provide connector views for this vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Diagrams > Page 3947
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor Monitor
The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S
sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream
HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean
to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper
output voltage. The following illustration shows that input is required from the Engine Coolant
Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air
Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel
System Monitor and Misfire Detection Monitor must also have completed successfully before the
HO2S Monitor is enabled.
1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel
ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich
of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor
evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper
function.
2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response
frequency are checked. Excessive voltage is
determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A
fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S
heater circuit fault is determined by turning the heater on and off and looking for a corresponding
change in the Output State Monitor (OSM) and by measuring the current going through the heater
circuit. The HO2S Monitor DTCs can be categorized as follows:
The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130,
P1131, P1132, P1150, P1151 and P1152.
The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153.
The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151
and P0156.
The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and
P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in
on-demand is DTC P1127.
The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129.
3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive
drive cycles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 3950
Heated Oxygen Sensor: Description and Operation PCM Inputs
HEATED OXYGEN SENSOR
Heated Oxygen Sensor (HO2S)
The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and
produces a variable voltage according to the amount of oxygen detected. A high concentration of
oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low
concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The
HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near
stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop
operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will
complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater
and heater control system are installed on some vehicles. The high power heater reaches closed
loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty
cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style
3.3 ohm heater.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Page 3951
Heated Oxygen Sensor: Service and Repair
EGO Sensor Wrench
SPECIAL SERVICE TOOL(S)
REMOVAL
NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and
Repair.
2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For
additional information, refer to Catalytic Converter.
4. Using the special tool, remove the HO2S.
NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or
equivalent to assist in removal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or
equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information >
Description and Operation > Page 3952
Syncro Positioning Tool
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3961
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3962
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3963
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3964
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 3965
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3971
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3972
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3973
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3974
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug >
04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 3975
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3980
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3981
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3982
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3988
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3989
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 3990
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3991
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR Bolts 8 - 10 Nm
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3992
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3993
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3994
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3995
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the differential pressure feedback EGR electrical connector.
3. Disconnect the differential pressure feedback EGR hoses.
4. Remove the bolts and the differential pressure feedback EGR.
INSTALLATION
1. Fit the differential pressure feedback EGR and loosely install the bolts.
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Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information >
Technical Service Bulletins > Page 3996
2. Tighten the bolts.
3. Connect the differential pressure feedback EGR hoses.
4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery
ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4000
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > PCM Inputs > Page 4003
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
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Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Description and
Operation > Page 4004
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Remove the Throttle Position (TP) sensor.
1 Disconnect the TP sensor electrical connector.
2 Remove the sensor.
NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 4008
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 4009
Digital Transmission Range Sensor: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 4010
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
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Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 4011
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position
Switch/Sensor, A/T] > Component Information > Specifications > Page 4012
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor Bolt 98 - 115 in.lb
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4018
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4019
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4020
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4021
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4022
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4023
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4024
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4025
Vehicle Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4026
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4027
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Information and Instructions > Page 4028
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4029
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4030
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4031
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 4032
Diagram 64-1
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Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Page 4033
Vehicle Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
Typical Vehicle Speed Sensor (VSS)
The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that
generates a waveform with a frequency that is proportional to the speed of the vehicle. If the
vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As
the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM
uses the frequency signal generated by the VSS (and other inputs) to control such parameters as
fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch
scheduling.
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Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4043
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4044
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4045
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4046
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4047
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4053
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4054
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4055
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4056
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4057
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4062
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4063
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4064
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4070
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4071
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4072
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4073
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR Bolts 8 - 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4074
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4075
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4076
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4077
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the differential pressure feedback EGR electrical connector.
3. Disconnect the differential pressure feedback EGR hoses.
4. Remove the bolts and the differential pressure feedback EGR.
INSTALLATION
1. Fit the differential pressure feedback EGR and loosely install the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4078
2. Tighten the bolts.
3. Connect the differential pressure feedback EGR hoses.
4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery
ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Nuts And Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 4083
Mass Air Flow Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 4084
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 4085
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 4086
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Loosen the air cleaner outlet tube clamp and position aside.
4. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and
Operation
Fuel Pressure Sensor/Switch: Description and Operation
FUEL RAIL PRESSURE SENSOR
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which
resistance changes with pressure. The electrical resistance of a strain gauge increases as
pressure increases, and decreases as pressure decreases. The varying resistance affects the
voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding
to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel
rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel
system. The differential fuel/intake manifold pressure together with measured fuel temperature
provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature
feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump
sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to
decrease.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4093
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump.
The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel
ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the
magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the
switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset
before restarting the vehicle. Refer to the Owner Guide for the location of the IFS.
Inertia Fuel Shutoff (IFS) Switch
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 4094
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery. For additional information, refer to Battery.
2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical
connector.
3. Remove the bolts and remove the IFS switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 4098
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> PCM Inputs > Page 4101
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation
> Page 4102
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Remove the Throttle Position (TP) sensor.
1 Disconnect the TP sensor electrical connector.
2 Remove the sensor.
NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor, Stud Bolt 19 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4107
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4108
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 4109
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the CMP sensor electrical connector.
2 Remove the CMP sensor stud bolt.
3 Remove the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 4113
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic
Engine Controls
Crankshaft Position Sensor: Description and Operation Electronic Engine Controls
The CKP sensor:
^ sends the PCM a signal indicating crankshaft position.
^ is essential for calculating spark timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Electronic
Engine Controls > Page 4116
Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel)
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Description and Operation > Page
4117
Crankshaft Position Sensor: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Crankshaft Position (CKP) sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor
has wear tabs that will wear off after several engine revolutions.
^ Be sure sensor wiring is routed away from the battery cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 4123
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Removal
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 4124
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the bearing and the gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair
> Ignition Lock Cylinder - Functional > Page 4125
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Note: Use a new ignition switch lock cylinder.
Follow the removal procedure in reverse order. ^
Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Bolt 25 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 4129
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 4130
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Specifications > Page 4131
Knock Sensor: Service and Repair
REMOVAL
1. Remove the lower in take manifold. For additional information, refer to Engine.
2. Remove the knock sensor.
1 Remove the bolt.
2 Remove the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Specifications
Fuel Pressure Test Port: Specifications
Fuel Pressure Relief Valve Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 4139
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 4140
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 4141
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel
supply line.
3. Remove the four bolts and the fuel supply line from the fuel supply manifold.
4. Remove the fuel supply line bracket bolt and the fuel supply line.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G, to aid installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > With 104 Pin Processor
Idle Speed: Specifications With 104 Pin Processor
Hot Idle ................................................................................................................................................
......................................................... 670 - 750 RPM
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > With 104 Pin Processor > Page 4146
Idle Speed: Specifications With 150 Pin Processor
With Automatic Transmission
Hot Idle ................................................................................................................................................
.................................................................. 750 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
.................................................................. 750 RPM
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Component Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions > Page 4154
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL SERVICE TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure.
NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service Precautions > Page 4155
Fuel Pressure Gauge
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order: Specifications
Coil Terminal-To-Cylinder Relationship
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications > Page 4159
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions
Ignition Cable: Service Precautions
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions > Page 4167
Ignition Cable: Service and Repair
Spark Plug Wire Remover
SPECIAL SERVICE TOOL(S)
REMOVAL
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug.
2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the
ignition coil.
3. Remove the spark plug wires.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service Precautions > Page 4168
1. To install, reverse the removal procedure.
CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the
exhaust manifold.
NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or
equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug and ignition
coil boots of the spark plug wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Spark Plug Gap
Spark Plug: Specifications
Spark Plug Gap 1.3 - 1.4 mm
RH Original Spark Plug AGRF22PG
LH Original Spark Plug AGRF22P
New Spark Plug (Either Side) AGSF22PP
Spark Plugs 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Spark Plug Gap > Page 4173
Spark Plug: Specifications
Spark Plug Gap 1.3 - 1.4 mm
RH Original Spark Plug AGRF22PG
LH Original Spark Plug AGRF22P
New Spark Plug (Either Side) AGSF22PP
Spark Plugs 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 4174
Spark Plug: Application and ID
RH Original Spark Plug Type ..............................................................................................................
.............................................................. AGRF22PG LH Original Spark Plug Type ............................
....................................................................................................................................................
AGRF22P New Spark Plug Type (Either Side) ...................................................................................
................................................................................. AGSF22PP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 4175
Spark Plug: Service and Repair
REMOVAL
1. Remove the spark plug wires. For additional information, refer to Ignition Cable.
2. Remove the spark plugs.
NOTE: ^
Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from.
New spark plugs can be used in any cylinder.
3. Inspect the spark plugs.
4. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading. For additional information, refer to the
Compression Pressure Limit Chart.
Compression Pressure Limit Chart
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 4179
Compression Check: Testing and Inspection
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle
until the engine is at normal operating temperature. Turn the ignition switch to the OFF position,
then remove all the spark plugs.
2. Set the throttle plates in the wide-open position. 3. Install a compression gauge such as the
Compression Tester in the No.1 cylinder. 4. Install an auxiliary starter switch in the starting circuit.
With the ignition switch in the OFF position, and using the auxiliary starter switch, crank
the engine a minimum of five compression strokes and record the highest reading. Note the
approximate number of compression strokes required to obtain the highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test-Test Results
The indicated compression pressures are considered within specification if the lowest reading
cylinder is within 75 percent of the highest reading.
Compression Pressure Limit Chart
If one or more cylinders reads low, squirt approximately one tablespoon of Super Premium SAE
5W-30 Motor Oil, XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G on top
of the pistons in the low-reading cylinders. Repeat the compression pressure check on these
cylinders.
Compression Test-Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 4180
2. If compression does not improve, valves are sticking or seating incorrectly. 3. If two adjacent
cylinders indicate low compression pressures and squirting oil on each piston does not increase
compression, the head gasket may
be leaking between cylinders. Engine oil or coolant in cylinders could result from this condition. Use
the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75 percent of the highest reading.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
The 4.0L Push Rod engine has hydraulic lifters and requires no valve clearance adjustments.
The 4.0L SOHC engine:
- Manufacturer does not indicate whether the type of valve arrangement for this engine.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Absolute Pressure Sensor >
Component Information > Description and Operation
Absolute Pressure Sensor: Description and Operation
THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR
Thermal Manifold Absolute Pressure (TMAP) Sensor
The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold
Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is
currently not being used. The MAP part of the sensor measures intake manifold air absolute
pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air
Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP)
sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced
into the intake manifold.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Specifications
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Nuts And Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Specifications > Page 4191
Mass Air Flow Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Specifications > Page 4192
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Specifications > Page 4193
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow Sensor <--> [Air
Flow Meter/Sensor] > Component Information > Specifications > Page 4194
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Loosen the air cleaner outlet tube clamp and position aside.
4. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Description and Operation
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE SENSOR
Intake Air Temperature (IAT)
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals
The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type
(Figure 37), are thermistor devices in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor >
Component Information > Description and Operation > Page 4198
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel spark and MAF.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above.
However, one is located before the supercharger at the air cleaner for standard OBD II/cold
weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control border-line spark and to help determine intercooler
efficiency.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle
Technical Service Bulletin # 03-3-5 Date: 030217
Engine Controls - No Start/Hard Start/Rough Idle
Article No. 03-3-5
02/17/03
DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS
FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 2000-2002 LS
MERCURY: 2000-2003 SABLE, MOUNTAINEER
ISSUE
Some vehicles, may exhibit drivability conditions.
These may include:
^ No start Difficult to start Stall
^ Low idle
^ Rough idle
^ High idle
^ Hesitation/surge while accelerating or at steady speed
These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction
Indicator Lamp (MIL). In some cases DTC and MIL may be evident.
ACTION
Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following
procedure is supplemental information to normal diagnostics to facilitate accurate identification of
malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling
problems, and Idle Speed Control System related DTC's.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4207
If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will
assist the technician making a correct repair the first time.
Perform normal diagnostics.
SERVICE INFORMATION
NOTE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4208
IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE
CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF
THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400,
698298
Disclaimer
IAC Diagnostic Service Tips - General
Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair
the drivability concern, but the long-term functionality of the valve is compromised.
For all drivability concerns, make certain the service writer obtains as much information as possible
from the customer as to the conditions causing drivability concern. Attached is a drivability concern
check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle.
NOTE
IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE
POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON
DECELERATION.
Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and
Lincoln LS.
1. Use the following conditions for the test described below:
^ Transmission in park
^ Engine temperature should be at least 190° F (88°C)
^ All accessories should be off steering wheel in the center position
^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system
^ Short and long term fuel trims less than 15%
^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission
Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the
chart in this TSB.
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure that there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird.
1. Use the following conditions for the test described below:
^ Transmission in park
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4209
^ Engine idle at approximately 650 RPM
^ Engine temperature should be at least 190° F (88° C)
^ All accessories and the engine cooling fan should be off
^ Steering wheel in the center position
^ EGRVR and EVAPDUTY CYCLE are zero
^ Short and long term fuel trims less than 15%
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
NOTE
IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650
RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER
THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND
CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM.
At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with
no purge flow (EVAPV duty cycle is 0%).
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
NOTE
IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY
CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER
DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN.
Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer,
Mountaineer, Explorer Sport and Explorer Sport Trac.
If no DTC's present check the following items in this order before examining the IAC valve:
^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB
^ Battery and fuse box power lead
^ Ground wire attachments
^ Wiring (wiggle test)
^ PCM voltage
^ Vacuum leaks
Examine AC valve under these conditions:
^ PCM updated to the latest available calibration
^ Transmission in park
^ Warm stabilized vehicle with engine temperature at least 190° F (88° C)
^ All accessories and cooling fan sh6uld be off
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4210
^ Steering wheel in the center position
^ EGVR and EVAPDC at zero, if the vehicle has an EGR system
^ Short and long term fuel trims (less than 15)
Perform the following steps in order:
1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3.
2. Allow vehicle to idle until the IACTRIM PID is 0.
NOTE
IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID
SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING
SHOULD BE TURNED OFF.
3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at
idle. The remainder of this TSB will help diagnose true root cause.
4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to
include the throttle body and air intake system) -is not operating properly.
NOTE
FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM
IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC.
IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns:
^ There are two primary causes of high idle:
1. Damaged IAC valves and
2. Vacuum leaks
^ AC valves can be damaged from engine induction backfires. Many times the customer may not
notice the induction backfire but will notice the high idle afterwards. Indications of valve damage
can be a shiny, almost polished appearance in the interior of the valve and a dislocated
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4211
pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1.
^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also
verify that the correct PCV valve is installed.
^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction
backfire can loosen or disconnect vacuum hoses.
^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear
normal in the service bay. If the duty cycle is below specification that is indicative that the engine is
receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to
restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS
(LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this
is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to
compensate.
IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle
Concerns:
^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on
the engine or obstruction in the air intake system could also reduce the engine RPMs.
^ There are four possible sources of friction load that can contribute to under speed error or low
idle concerns.
1. Power Steering Load
2. Air Conditioning Load
3. Electrical Load
4. Automatic Transmission Torque Converter Load
EAC Diagnostic Service Tips - Rough Idle
Concerns:
^ Rough idle concerns are often a result of a lean running condition
^ Another possible cause is contamination build up on the MAF sensor
EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start
^ While performing diagnostics, the technician should ensure that the fuel system is working
correctly for all engines with hard start/crank no-start complaints.
^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED
pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure
test:
^ Perform the KOEO fuel pressure test as specific in the PC/ED manual.
^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55
psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the
start of the test.
^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test.
^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible
after pump shut off, no more than 5 minutes after the start of the test.
NOTE
RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED
USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC.
IAC Diagnostic Service Tips - High Idle RPM at Start Up:
^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If
DTC 1506 is not present, this indicates that there is no fault present with the IAC.
^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast
idle (1600-2500 RPM that decreases slowly). No
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4212
repairs should be attempted because this is a normal temporary PCM calibration strategy to
prevent spark plug fouling during plant/transportation operation. The calibration will permanently
revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A
brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle
has been below 4 miles at a time.
IAC Diagnostic Service Tips - EAC Valve Noise Issues
For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire.
NOTE
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
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ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS
FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE
IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE
IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE,
COMPARE AGAINST A LIKE VEHICLE.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle
Technical Service Bulletin # 03-3-5 Date: 030217
Engine Controls - No Start/Hard Start/Rough Idle
Article No. 03-3-5
02/17/03
DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS
FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 2000-2002 LS
MERCURY: 2000-2003 SABLE, MOUNTAINEER
ISSUE
Some vehicles, may exhibit drivability conditions.
These may include:
^ No start Difficult to start Stall
^ Low idle
^ Rough idle
^ High idle
^ Hesitation/surge while accelerating or at steady speed
These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction
Indicator Lamp (MIL). In some cases DTC and MIL may be evident.
ACTION
Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following
procedure is supplemental information to normal diagnostics to facilitate accurate identification of
malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling
problems, and Idle Speed Control System related DTC's.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4219
If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will
assist the technician making a correct repair the first time.
Perform normal diagnostics.
SERVICE INFORMATION
NOTE
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4220
IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE
CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF
THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400,
698298
Disclaimer
IAC Diagnostic Service Tips - General
Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair
the drivability concern, but the long-term functionality of the valve is compromised.
For all drivability concerns, make certain the service writer obtains as much information as possible
from the customer as to the conditions causing drivability concern. Attached is a drivability concern
check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle.
NOTE
IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE
POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON
DECELERATION.
Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and
Lincoln LS.
1. Use the following conditions for the test described below:
^ Transmission in park
^ Engine temperature should be at least 190° F (88°C)
^ All accessories should be off steering wheel in the center position
^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system
^ Short and long term fuel trims less than 15%
^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission
Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the
chart in this TSB.
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure that there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird.
1. Use the following conditions for the test described below:
^ Transmission in park
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4221
^ Engine idle at approximately 650 RPM
^ Engine temperature should be at least 190° F (88° C)
^ All accessories and the engine cooling fan should be off
^ Steering wheel in the center position
^ EGRVR and EVAPDUTY CYCLE are zero
^ Short and long term fuel trims less than 15%
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
NOTE
IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650
RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER
THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND
CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM.
At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with
no purge flow (EVAPV duty cycle is 0%).
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
NOTE
IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY
CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER
DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN.
Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer,
Mountaineer, Explorer Sport and Explorer Sport Trac.
If no DTC's present check the following items in this order before examining the IAC valve:
^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB
^ Battery and fuse box power lead
^ Ground wire attachments
^ Wiring (wiggle test)
^ PCM voltage
^ Vacuum leaks
Examine AC valve under these conditions:
^ PCM updated to the latest available calibration
^ Transmission in park
^ Warm stabilized vehicle with engine temperature at least 190° F (88° C)
^ All accessories and cooling fan sh6uld be off
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4222
^ Steering wheel in the center position
^ EGVR and EVAPDC at zero, if the vehicle has an EGR system
^ Short and long term fuel trims (less than 15)
Perform the following steps in order:
1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3.
2. Allow vehicle to idle until the IACTRIM PID is 0.
NOTE
IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID
SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING
SHOULD BE TURNED OFF.
3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at
idle. The remainder of this TSB will help diagnose true root cause.
4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to
include the throttle body and air intake system) -is not operating properly.
NOTE
FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM
IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC.
IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns:
^ There are two primary causes of high idle:
1. Damaged IAC valves and
2. Vacuum leaks
^ AC valves can be damaged from engine induction backfires. Many times the customer may not
notice the induction backfire but will notice the high idle afterwards. Indications of valve damage
can be a shiny, almost polished appearance in the interior of the valve and a dislocated
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4223
pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1.
^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also
verify that the correct PCV valve is installed.
^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction
backfire can loosen or disconnect vacuum hoses.
^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear
normal in the service bay. If the duty cycle is below specification that is indicative that the engine is
receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to
restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS
(LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this
is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to
compensate.
IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle
Concerns:
^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on
the engine or obstruction in the air intake system could also reduce the engine RPMs.
^ There are four possible sources of friction load that can contribute to under speed error or low
idle concerns.
1. Power Steering Load
2. Air Conditioning Load
3. Electrical Load
4. Automatic Transmission Torque Converter Load
EAC Diagnostic Service Tips - Rough Idle
Concerns:
^ Rough idle concerns are often a result of a lean running condition
^ Another possible cause is contamination build up on the MAF sensor
EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start
^ While performing diagnostics, the technician should ensure that the fuel system is working
correctly for all engines with hard start/crank no-start complaints.
^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED
pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure
test:
^ Perform the KOEO fuel pressure test as specific in the PC/ED manual.
^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55
psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the
start of the test.
^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test.
^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible
after pump shut off, no more than 5 minutes after the start of the test.
NOTE
RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED
USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC.
IAC Diagnostic Service Tips - High Idle RPM at Start Up:
^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If
DTC 1506 is not present, this indicates that there is no fault present with the IAC.
^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast
idle (1600-2500 RPM that decreases slowly). No
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4224
repairs should be attempted because this is a normal temporary PCM calibration strategy to
prevent spark plug fouling during plant/transportation operation. The calibration will permanently
revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A
brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle
has been below 4 miles at a time.
IAC Diagnostic Service Tips - EAC Valve Noise Issues
For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire.
NOTE
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) >
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03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 4225
ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS
FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE
IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE
IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE,
COMPARE AGAINST A LIKE VEHICLE.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor, Stud Bolt 19 Nm
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Component Information > Specifications > Page 4229
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 4230
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 4231
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the CMP sensor electrical connector.
2 Remove the CMP sensor stud bolt.
3 Remove the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component
Information > Diagrams
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Clutch Switch, ECM > Component
Information > Diagrams > Page 4235
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION SWITCH
Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches
The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch
pedal position and, in some manual transmission applications, both the clutch pedal engagement
position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference
Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP
signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed,
indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output
voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1
volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or
PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the
clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP
switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the
5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load
information in mass air flow and fuel calculations.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 15 Nm
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Sensor/Switch (For Computer) > Component Information > Specifications > Page 4239
Coolant Temperature Sensor/Switch (For Computer): Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 4240
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 4241
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Remove the thermostat and housing. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the Engine Coolant Temperature (ECT) sensor.
1 Disconnect the connector.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolts 10 Nm
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Component Information > Specifications > Page 4245
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Description and Operation > Electronic Engine Controls
Crankshaft Position Sensor: Description and Operation Electronic Engine Controls
The CKP sensor:
^ sends the PCM a signal indicating crankshaft position.
^ is essential for calculating spark timing.
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Component Information > Description and Operation > Electronic Engine Controls > Page 4248
Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel)
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Crankshaft Position Sensor: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Crankshaft Position (CKP) sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor
has wear tabs that will wear off after several engine revolutions.
^ Be sure sensor wiring is routed away from the battery cable.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Diagrams > Diagram Information and Instructions
Data Link Connector: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Component Information > Diagrams > Diagram Information and Instructions > Page 4255
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Component Information > Diagrams > Diagram Information and Instructions > Page 4256
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Data Link Connector: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Component Information > Diagrams > Page 4270
Data Link Connector: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Module Communications Network / Information Bus.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM
Programming Procedures
Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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[Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM
Programming Procedures > Page 4275
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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[Engine Control Module] > Component Information > Technical Service Bulletins > Engine Controls - General PCM
Programming Procedures > Page 4276
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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[Engine Control Module] > Component Information > Technical Service Bulletins > Page 4277
Powertrain Control Module: Specifications
PCM Connector 5 - 7 Nm
Powertrain Control Module Connector Bolt 7 Nm
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[Engine Control Module] > Component Information > Technical Service Bulletins > Page 4278
Powertrain Control Module: Locations
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Powertrain Control Module: Diagrams
Part (1 Of 3)
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Part (2 Of 3)
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Part (3 Of 3)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Description and Operation > General Description and Operation
Powertrain Control Module: Description and Operation General Description and Operation
The PCM performs the following functions:
^ accepts input from various engine sensors to compute the required fuel flow rate necessary to
maintain a prescribed air/fuel ratio throughout the entire engine operational range.
^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel.
^ determines and compensates for the age of the vehicle and its uniqueness, also automatically
senses and compensates for changes in altitude.
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[Engine Control Module] > Component Information > Description and Operation > General Description and Operation >
Page 4285
Powertrain Control Module: Description and Operation Standard Models (Non BI-Fuel)
POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO)
The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem
generates vehicle speed information for distribution to the vehicle's electrical/electronic modules
and subsystems that require vehicle speed data. This subsystem senses the transmission output
shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired
signal or as a multiplexed data message.
The key features of the PCM-VSO system are to:
^ Infer vehicle movement from the output shaft sensor signal
^ Convert transmission output shaft rotational information to vehicle speed information
^ Compensate for tire size and axle ratio with a programmed calibration variable
^ Utilize a transfer case sensor for four wheel drive applications
^ Distribute vehicle speed information as a multiplexed message and/or an analog signal
The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft
Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is
sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per
mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into
the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing
changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information
can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM,
or by Speed and Odometer SCP multiplexed data messages.
The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT.
Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for
speed and distance data are transmitted as separate SCP messages over the SCP multiplex link.
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[Engine Control Module] > Component Information > Service and Repair > Flash Electrically Eraseable Programmable Read
Only Memory
Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read
Only Memory
Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM
Description
Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an
Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the
vehicle strategy including calibration information specific to the vehicle and is capable of being
reprogrammed or reflashed repeatedly.
As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM as under Programming the VID Block for
a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block
not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can
also be tailored to accommodate various hardware changes made to the vehicle since production.
Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of
Acceptable Range. This is described under Making Changes to the VID Block and also under
Making Changes to the PCM Calibration. The VID block contains many items used by the strategy
for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane,
fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel
drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle
hardware and supported by the VID block will be displayed on the scan tool.
When changing items in the VID block, the strategy will place range limits on certain items such as
tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When
this limit is reached, the scan tool will display a message indicating the need to flash the PCM
again to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other
Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic
tool manufacturers users manual for details.
Programming the VID Block for a Replacement PCM
A new PCM will contain the latest strategy and calibration level for a particular vehicle. However,
the VID block will be blank and will need programming. There are two procedures available. The
first is an automatic data transfer from the old PCM to the new PCM and the second is manual data
entry into the new PCM.
Automatic data transfer will be performed if the old PCM is capable of communicating. This is done
by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The
stored data can now be downloaded to the new PCM after it has been replaced.
Manual data entry must be performed if the old module is damaged and is incapable of
communicating. Remove and replace the old PCM. You may be instructed to contact the "AS
BUILT" data center for the information needed to manually update the VID block with the scan tool.
Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M
technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed
World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or
"Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool.
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Powertrain Control Module: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Powertrain Control Module (PCM) electrical connector.
3. Remove the nuts and the PCM cover.
4. Remove the PCM.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Temperature Sensor >
Component Information > Description and Operation > Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
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Component Information > Description and Operation > Cylinder Head Temperature Sensor > Page 4293
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component
Information > Description and Operation
Fuel Level Sensor: Description and Operation
The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the
action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is
high, the resistance is high.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Pump Signal > Component
Information > Description and Operation
Fuel Pump Signal: Description and Operation
FUEL PUMP MONITOR
Applications Using a Fuel Pump Relay for Fuel Pump On/Off Control
The Fuel Pump Monitor (FPM) circuit is spliced into the Fuel Pump Power (FP PWR) circuit and is
used by the PCM for diagnostic purposes. The PCM sources a low current voltage down the FPM
circuit. With the fuel pump off, this voltage is pulled low by the path to ground through the fuel
pump. With the fuel pump off and the FPM circuit low, the PCM can verify that the FPM circuit and
the FP PWR circuit are complete from the FPM splice through the fuel pump to ground. This also
confirms that the FP PWR or FPM circuits are not shorted to power. With the fuel pump on, voltage
is now being supplied from the fuel pump relay to the FP PWR and FPM circuits. With the fuel
pump on and the FPM circuit high, the PCM can verify that the FP PWR circuit from the fuel pump
relay to the FPM splice is complete. It can also verify that the fuel pump relay contacts are closed
and there is a B+ supply to the fuel pump relay.
Fuel Pump Driver Module Applications
Fuel Pump Driver Module Duty Cycle Signals, Part 1
Fuel Pump Driver Module Duty Cycle Signals, Part 2
The Fuel Pump Driver Module (FPDM) communicates diagnostic information to the Powertrain
Control Module (PCM) through the Fuel Pump Monitor (FPM) circuit. This information is sent by the
FPDM as a duty cycle signal. The three duty cycle signals that may be sent are listed in the table.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 4303
Fuel Tank Pressure Sensor: Service Precautions
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 4304
Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure Sensor
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor
(Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles
equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank
pressure by forcing the system to purge.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor >
Component Information > Locations > Page 4305
Fuel Tank Pressure Sensor: Service and Repair
REMOVAL
1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction.
2. Remove the fuel tank pressure sensor.
1 Disconnect the electrical connector.
2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the
fuel tank.
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test the evaporative emission system. For additional information, refer to Evaporative
Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection/Component Tests and General Diagnostics/Component
Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emissions repair verification drive cycle. For additional information,
refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control
Systems/Evaporative Emissions System/Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications
Idle Air Control Valve: Specifications
Idle Air Control Valve Bolts 10 Nm
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4309
Idle Air Control Valve: Description and Operation
IDLE AIR CONTROL VALVE
Nippondenso Idle Air Control (IAC) Valve Assembly
Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter
The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed
and provides a dashpot function. The IAC valve assembly meters intake air around the throttle
plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the
desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle.
The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The
PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the
desired rpm.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4310
Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors
On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount
of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low
speed and light load conditions.
NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED.
The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the
internal diode is measured in crossed terminal position with a digital multimeter, there will be an
incorrect or negative reading. It is important that the mating component and harness connectors
correctly oriented. Diagnostic procedures emphasize this importance.
The PCM uses the IAC valve assembly to control:
^ No touch start
^ Cold engine fast idle for rapid warm-up
^ Idle (corrects for engine load)
^ Stumble or stalling on deceleration (provides a dashpot function)
^ Over-temperature idle boost.
^ Air Assist to Injectors.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4311
Idle Air Control Valve: Testing and Inspection
1. Open the hood. 2. Verify the condition by operating the vehicle for a short time.
NOTE: ^
Key symptom is elevated idle speed while noise is occurring.
^ "Snapping" the throttle can induce the noise.
3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4.
While the noise is occurring, either place an Engine EAR probe near the IAC valve and the inlet
tube, or create a 6.35 mm (0.25 in) - 12.7 mm
(0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise,
install a new IAC valve.
5. Test the vehicle for normal operation.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4312
Idle Air Control Valve: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Disconnect the idle air control (IAC) valve electrical connector.
4. Remove the IAC valve and discard the gasket.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Install a new IAC valve gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network
<--> [Information Bus] > Component Information > Specifications
Multiplex Communication Network: Specifications
Heat shrink tube overlap 12.7 mm
Wire insulation removal length (twist side) 37.2 mm
Wire insulation removal length (receiving side) 19.5 mm
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<--> [Information Bus] > Component Information > Specifications > Page 4316
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network
<--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions
Multiplex Communication Network: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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<--> [Information Bus] > Component Information > Diagrams > Diagram Information and Instructions > Page 4324
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Multiplex Communication Network: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Diagram 14-1
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network
<--> [Information Bus] > Component Information > Description and Operation > Description and Operation
Multiplex Communication Network: Description and Operation
The vehicle has two separate module communication networks. The Standard Corporate Protocol
(SCP) which is an unshielded twisted pair cable (data bus plus, circuit 914 [T/O] and data bus
minus, circuit 915 [P/LB]) and the International Standards Organization (ISO) 9141 Network via a
single wire (circuit 70 [LB/W]). Both networks can be connected to scan tool at one connector
called the Data Link Connector (DLC). This makes troubleshooting these systems easier by
allowing one smart tester to be able to diagnose and control any module on the two networks from
one connector. The DLC can
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be found under the instrument panel between the steering column and the radio.
The ISO 9141 communication network does not permit inter-module communication. When the
scan tool communicates to modules on the ISO 9141 communication network, the scan tool must
ask for all information; the modules cannot initiate communications.
The SCP will remain operational even with the severing of one of the bus wires. Communications
will also continue if one of the bus wires is shorted to ground or battery positive voltage (B+) or a
termination resistor is lost. This faulted condition is detected and reported to the host by the
module's network bus interface circuits.
Unlike the SCP, the ISO 9141 communication network will not function if the wire is shorted to
ground or battery positive voltage (B+). Also, if one of the modules on the ISO 9141 communication
network loses power or shorts internally, communications to that module will fail.
There are three modules linked to the SCP communication network and seven modules linked to
the ISO 9141 communication network.
SCP Communication Network
The Powertrain Control Module (PCM) is on the SCP communication network. The PCM controls
the engine for better fuel economy, emissions control and failure mode detection and storage.
The Passive Anti-theft System (PATS) module is on the SCP communication network. The PATS
module contains circuitry to connect the vehicle electrical system, the transceiver module, the
vehicle module communications network and the vehicle theft indicator located in the instrument
cluster. The PATS module uses a microprocessor to control the system functions. The PATS
module microprocessor stores the ignition key codes in non-volathe memory. The PATS module
can be diagnosed through the data link connector. For additional information, refer to Antitheft and
Alarm Systems.
The Electronic Automatic Temperature Control (EATC) module is linked to the SCP communication
network. The EATC module controls automatic climate functions that maintain the interior at a
constant temperature setting. For additional information, refer to Heating and Air Conditioning.
ISO 9141 Communication Network
The Restraint Control Module (RCM) module is on the ISO 9141 communication network. The
RCM controls the deployment of the air bags based on sensor input. For additional information,
refer to Air Bag Systems.
The Parking Aid Module (PAM) is on the ISO 9141 communication network. The PAM controls the
parking aid system For additional information, See: Accessories and Optional Equipment/Collision
Avoidance and Parking Assist Systems
The Generic Electronic Module (GEM)/Central Timer Module (CTM) is on the ISO 9141
communication network. The GEM is equipped on vehicles with four-wheel drive or vehicles with
power windows. The CTM is equipped on vehicles with two-wheel drive or vehicles without power
windows. The GEM controls a variety of systems:
^ 4x4
^ Windshield wipers
^ Courtesy lamps
^ One touch down power windows, etc.
^ Warning chimes/lamps
For additional information, refer to Multifunction Electronic Control Module. The Remote Anti-theft
Personality (RAP) module is on the ISO 9141 communication network. The RAP module controls
the keyless remote entry and active anti-theft of the vehicle. For additional information, refer to
Keyless Entry and Antitheft and Alarm Systems.
The 4-wheel anti-lock brake control module is on the ISO 9141 communication network. The
4-wheel anti-lock brake control module controls the brake pressure to the four wheels to keep the
vehicle under control while braking. For additional information, refer to Antilock Brake System.
The air suspension system is a computer controlled suspension system. The rear shock absorber
contains an integrated air spring. The rear air springs provide automatic load leveling and a ride
adjustment with a total span of 50 mm (2 in).
The air suspension control module programming has a time delay compensation for normal
suspension travel over rough roads so the air suspension system will not attempt to continuously
adjust vehicle ride height.
There is one height sensor mounted in the rear of the vehicle. The height sensors have a total
travel range of 80 mm (3 in). For additional information, refer to Electronic Level Control.
The Driver Seat Module (DSM) is connected on the SCP communication network. The DSM
controls the power seat and memory functions. For additional information, refer to Seats.
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Multiplex Communication Network: Description and Operation Principles of Operation
Some modules support the ability to change specified factory configuration settings and preset
preference items. The process used to change the settings and customer preference items is
module configuration. The methods of module configuration used on these vehicles are:
^ Tire Size and Axle Ratio
^ Operational Strategy (4x2/4x4)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network
<--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network
Multiplex Communication Network: Testing and Inspection Module Communications Network
Initial Inspection
1. Verify the customer concern. 2. Visually inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) Fuse 5 (10A)
^ Damaged wiring harness
^ Loose or corroded connectors
^ 4-wheel anti-lock brake control module
^ Restraint Control Module (RCM)
^ Generic Electronic Module (GEM)/Central Timer Module (CTM)
^ Powertrain control module (PCM)
^ Parking aid module (PAM) (optional)
^ Remote Anti-theft Personality (RAP) module (optional)
^ Air suspension control module (optional)
^ Passive Anti-theft System (PATS) module
^ Driver Seat Module (DSM) (optional)
^ Electronic Automatic Temperature Control (EATC) module (optional)
3. If the concern remains after the inspection, connect the scan tool to the Data Link Connector
(DLC) located beneath the instrument panel and
select the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with
the vehicle: ^
check that the program card is properly installed.
^ check the connections to the vehicle.
^ check the ignition switch position is in RUN.
If the scan tool still does not communicate with the vehicle, go to Pinpoint Test M. See: Pinpoint
Tests/Pinpoint Tests/Test M: No Module/Network Communication - No Power to Scan Tool
4. Go to Pinpoint Test PC. See: Pinpoint Tests/Pinpoint Test PC (Precheck)
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PC1
Test A: 4WABS Control Module Does Not Respond to Diagnostic Tool
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A1 - A2
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A3 - A4
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A5 - A6
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B1 - B2
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C1 - C2
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D1 - D2
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D3 - D4
Test E: PCM Does Not Respond to the Diagnostic Tool
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E1 - E2
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E3
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E4 - E5
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E6
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F1 - F2
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G1 - G2
Test H: DSM No Response
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H1 - H2
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H3 - H4
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H5 - H6
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I1 - I2
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I3 - I4
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J1 - J2
Test K: No Module/Network Communication - ISO 9141 Network
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K1 - K2
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K3 - K4
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K5
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K6 - K7
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K8
K9
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K10 - K11
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K12 - K13
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K14 - K15
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K16
K17
K18
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K19 - K20
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K21
K22
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K23
Test L: No Module/Network Communication - SCP Network
L1
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L2 - L3
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L4
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L5
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L6
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L7
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L8
M1
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M2 - M4
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<--> [Information Bus] > Component Information > Testing and Inspection > Module Communications Network > Page 4380
Multiplex Communication Network: Testing and Inspection Module Configuration
Inspection and Verification
1. Visually inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Damaged wiring harness
^ Loose or corroded connectors
^ 4-wheel Anti-lock Brake Control Module (4WABS)
^ Generic Electronic Module (GEM)
2. If the concern remains after inspection, connect the scan tool to the Data Link Connector (DLC)
located beneath the instrument panel and select
the vehicle to be tested from the scan tool menu. If the scan tool does not communicate with the
vehicle: ^
check that the program card is correctly installed.
^ check the connections to the vehicle.
^ check the ignition switch is in RUN position.
3. If the scan tool still does not communicate with the vehicle, refer to Module Communication
Network (Information Bus). 4. Refer to the Symptom Chart. See: Diagnosis By Symptom
Customer Preference Items
NOTE:
^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts.
^ Make sure module is listed as supporting customer preference items and supports the specific
item to be configured in the Module Configuration Index.
1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the customer
preference item to be programmed. Refer to the Module Configuration Index. See: Scan Tool
Testing/Module Configuration Index
3. Select Customer Preference Items on the scan tool. 4. Select Module Option Content. 5. Select
the item to be enabled or disabled. 6. Enable or disable the item as necessary to reflect the
customer preference.
Operational Strategy
NOTE:
^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts.
^ Make sure module is listed as supporting tire size and axle ratio configuration in the Module
Configuration Index.
1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the
Operational Strategy to be programmed. Refer to the Module Configuration Index. See: Scan Tool
Testing/Module Configuration Index
3. Select Operational Strategy. 4. Select the vehicle. 5. Select 4x4 for a 4x4 vehicle. Select 4x2 for
a 4x2 vehicle.
Tire Size and Axle Ratio
NOTE:
^ If using the WDS, select Module Configuration and Programming, then follow the screen prompts.
^ Make sure module is listed as supporting tire size and axle ratio configuration in the Module
Configuration Index.
1. Select Service Bay Functions on the scan tool. 2. Select the module that contains the Tire Size
and Axle Ratio configuration. 3. Select Customer Preference Items. 4. Select Tire Size and Axle
Ratio on the scan tool. 5. Select the vehicle.
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6. Enter the correct value for the vehicle according to the chart and finish the routine. If the tire size
is not listed on the chart, Go to step 7. 7. Position the vehicle on level ground. Make sure the load
weight is within the specific vehicle application.
NOTE: The following steps will calculate tire revolutions per mile. This will provide the number that
needs to be entered on the scan tool.
8. Inflate the tires to the specified rating.
NOTE: Tire pressure must be set when the tires are cold.
9. Measure the rear tire height from the ground to the top of the tire in inches.
10. Divide 20,168 by the tire height measurement. This is the revolutions per mile. 11. Enter the
revolutions per mile (rev/mile) on the scan tool and finish the routine.
Module Configuration Index
NOTE: Do not contact the As-Built Data Center unless the scan tool instructs you to do so. The
scan tool will not allow you to use as-built data information unless the scan tool first prompts you
for the As-Built Data Center information.
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A1 - A3
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<--> [Information Bus] > Component Information > Testing and Inspection > Page 4384
Multiplex Communication Network: Service and Repair
Communication Circuit Wiring Repair
Heat Gun
SPECIAL SERVICE TOOLS
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Strip the wires.
3. Solder the wires
1 Install the heat shrink tube.
2 Twist the wires together.
3 Solder the wires together.
NOTE: Use Rosin Core Mildly Activated (RMA) solder, not acid core solder.
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4. Bend the wires back in a straight line.
NOTE: Wait for the solder to cool before moving the wires.
5. Position the (A) heat shrink tube over the (B) wire repair.
^ Overlap the heat shrink tube on both wires.
6. Use the heat gun to heat the repaired area until adhesive flows out both ends of the heat shrink
tube. 7. Reconnect the battery ground cable.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network
<--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment
Multiplex Communication Network: Tools and Equipment
Recommended Tools
Heat Gun
Recommended Supplies
Raychem SCT(R) heat shrink tubing, Motorcraft part number WT-5627
.................................................................................................. ESB-M99D56-A2
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Multiplex Communication Network
<--> [Information Bus] > Component Information > Tools and Equipment > Tools and Equipment > Page 4388
Multiplex Communication Network: Tools and Equipment Diagnostic Special Service Tool(S)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Specifications
Knock Sensor: Specifications
Knock Sensor Bolt 25 Nm
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Information > Specifications > Page 4392
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Specifications > Page 4393
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Specifications > Page 4394
Knock Sensor: Service and Repair
REMOVAL
1. Remove the lower in take manifold. For additional information, refer to Engine.
2. Remove the knock sensor.
1 Remove the bolt.
2 Remove the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Powertrain Control Module Power Relay: Locations
Part (1 Of 2)
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Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4398
Part (2 Of 2)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 4399
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp >
Component Information > Locations > Page 4403
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR LAMP (MIL)
Malfunction Indicator Lamp (MIL)
Check Engine, Service Engine Soon Or ISO Standard Engine Symbol
The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control
Module (PCM) has detected an OBD II emission-related component or system fault. When this
occurs, an OBD II Diagnostic Trouble Code (DTC) will be set.
^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or ISO standard engine symbol (Figure 16).
^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position.
^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster
proveout for approximately 4 seconds.
^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present.
- The instrument cluster will illuminate the MIL if the PCM does not send a control message to the
instrument cluster.
- The PCM is operating in the Hardware Limited Operation Strategy (HLOS).
- The MIL circuit is shorted to ground.
^ If the MIL remains off (during the bulb check): Bulb is damaged.
- MIL circuit is open.
^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three
consecutive drive cycles must be completed without a fault.
^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection.
^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist.
^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground
in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Diagnosis > Page 4408
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability
Diagnosis > Page 4409
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Heated Oxygen Sensor: Specifications
Heated Oxygen Sensor 41 Nm
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Heated Oxygen Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4436
Heated Oxygen Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4437
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4438
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4439
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4440
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4441
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4442
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 4443
Heated Oxygen Sensor: Connector Views
Ford does not provide connector views for this vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Diagrams > Page 4444
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor Monitor
The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S
sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream
HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean
to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper
output voltage. The following illustration shows that input is required from the Engine Coolant
Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air
Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel
System Monitor and Misfire Detection Monitor must also have completed successfully before the
HO2S Monitor is enabled.
1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel
ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich
of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor
evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper
function.
2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response
frequency are checked. Excessive voltage is
determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A
fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S
heater circuit fault is determined by turning the heater on and off and looking for a corresponding
change in the Output State Monitor (OSM) and by measuring the current going through the heater
circuit. The HO2S Monitor DTCs can be categorized as follows:
The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130,
P1131, P1132, P1150, P1151 and P1152.
The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153.
The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151
and P0156.
The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and
P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in
on-demand is DTC P1127.
The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129.
3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive
drive cycles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Description and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page
4447
Heated Oxygen Sensor: Description and Operation PCM Inputs
HEATED OXYGEN SENSOR
Heated Oxygen Sensor (HO2S)
The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and
produces a variable voltage according to the amount of oxygen detected. A high concentration of
oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low
concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The
HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near
stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop
operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will
complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater
and heater control system are installed on some vehicles. The high power heater reaches closed
loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty
cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style
3.3 ohm heater.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Description and Operation > Page 4448
Heated Oxygen Sensor: Service and Repair
EGO Sensor Wrench
SPECIAL SERVICE TOOL(S)
REMOVAL
NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and
Repair.
2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For
additional information, refer to Catalytic Converter.
4. Using the special tool, remove the HO2S.
NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or
equivalent to assist in removal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or
equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Heated Oxygen Sensor <-->
[Oxygen Sensor] > Component Information > Description and Operation > Page 4449
Syncro Positioning Tool
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4458
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4459
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4460
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4461
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube
Mounted EGR Pressure Sensor Defect > Page 4462
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4468
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4469
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4470
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4471
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4472
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4477
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4478
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pressure
Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4479
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback
Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback
Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4485
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback
Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4486
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for Pressure Feedback
Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4487
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4488
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR Bolts 8 - 10 Nm
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4489
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4490
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4491
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4492
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the differential pressure feedback EGR electrical connector.
3. Disconnect the differential pressure feedback EGR hoses.
4. Remove the bolts and the differential pressure feedback EGR.
INSTALLATION
1. Fit the differential pressure feedback EGR and loosely install the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust
Sensor, EGR > Component Information > Technical Service Bulletins > Page 4493
2. Tighten the bolts.
3. Connect the differential pressure feedback EGR hoses.
4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery
ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Engine Controls - General PCM Programming Procedures
Powertrain Control Module: Technical Service Bulletins Engine Controls - General PCM
Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4499
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 4500
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4501
Powertrain Control Module: Specifications
PCM Connector 5 - 7 Nm
Powertrain Control Module Connector Bolt 7 Nm
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4502
Powertrain Control Module: Locations
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4503
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4504
Powertrain Control Module: Diagrams
Part (1 Of 3)
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4505
Part (2 Of 3)
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Technical
Service Bulletins > Page 4506
Part (3 Of 3)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and
Operation > General Description and Operation
Powertrain Control Module: Description and Operation General Description and Operation
The PCM performs the following functions:
^ accepts input from various engine sensors to compute the required fuel flow rate necessary to
maintain a prescribed air/fuel ratio throughout the entire engine operational range.
^ outputs a command to the fuel injectors to meter the appropriate quantity of fuel.
^ determines and compensates for the age of the vehicle and its uniqueness, also automatically
senses and compensates for changes in altitude.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Description and
Operation > General Description and Operation > Page 4509
Powertrain Control Module: Description and Operation Standard Models (Non BI-Fuel)
POWERTRAIN CONTROL MODULE - VEHICLE SPEED OUTPUT (VSO)
The PCM-VSO (Powertrain Control Module - Vehicle Speed Output) speed signal subsystem
generates vehicle speed information for distribution to the vehicle's electrical/electronic modules
and subsystems that require vehicle speed data. This subsystem senses the transmission output
shaft speed with a sensor. The data is processed by the PCM, and distributed as a hard-wired
signal or as a multiplexed data message.
The key features of the PCM-VSO system are to:
^ Infer vehicle movement from the output shaft sensor signal
^ Convert transmission output shaft rotational information to vehicle speed information
^ Compensate for tire size and axle ratio with a programmed calibration variable
^ Utilize a transfer case sensor for four wheel drive applications
^ Distribute vehicle speed information as a multiplexed message and/or an analog signal
The signal from a non-contact shaft sensor (Output Shaft Sensor--OSS or Transfer Case Shaft
Sensor--TCSS) mounted on the transmission (automatics, manuals, or 4X4 transfer cases) is
sensed directly by the PCM. The PCM converts the OSS or TCSS information to 8000 pulses per
mile, based on a tire and axle ratio conversion factor. This conversion factor is programmed into
the PCM at the time the vehicle is assembled and can be reprogrammed in the field for servicing
changes in the tire size and axle ratio. The PCM transmits the computed vehicle speed and
distance traveled information to all the vehicle speed signal users on the vehicle. VSO information
can be transmitted by a hard-wired interface between the vehicle speed signal user and the PCM,
or by Speed and Odometer SCP multiplexed data messages.
The VSO hard-wired signal wave form is a DC square wave with a voltage level of 0 to VBAT.
Typical output operating range is 2.22Hz per MPH (1.3808 Hz pr 1 Km/h). Multiplexed data for
speed and distance data are transmitted as separate SCP messages over the SCP multiplex link.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
Repair > Flash Electrically Eraseable Programmable Read Only Memory
Powertrain Control Module: Service and Repair Flash Electrically Eraseable Programmable Read
Only Memory
Flash Electrically Eraseable Programmable Read Only Memory - Flash EEPROM
Description
Flash Electrically Eraseable Programmable Read Only Memory (EEPROM) is contained in an
Integrated Circuit (IC) internal to the Powertrain Control Module (PCM). The EEPROM contains the
vehicle strategy including calibration information specific to the vehicle and is capable of being
reprogrammed or reflashed repeatedly.
As part of the calibration there is an area referred to as the Vehicle Identification (VID) block. The
VID block must be programmed when replacing the PCM as under Programming the VID Block for
a Replacement PCM. Failure to perform this procedure may generate fault code: P1639, VID Block
not programmed or is corrupt. The VID block in an existing Powertrain Control Module (PCM). can
also be tailored to accommodate various hardware changes made to the vehicle since production.
Failure to perform this procedure properly may generate fault code: P1635, Tire/Axle Ratio out of
Acceptable Range. This is described under Making Changes to the VID Block and also under
Making Changes to the PCM Calibration. The VID block contains many items used by the strategy
for a variety of functions. Some of these items include the VIN number, octane adjust, fuel octane,
fuel type, vehicle speed limit, tire size, axle ratio, the presence of speed control and four wheel
drive electronic shift on the fly versus manual shift on the fly. Only items applicable to vehicle
hardware and supported by the VID block will be displayed on the scan tool.
When changing items in the VID block, the strategy will place range limits on certain items such as
tire and axle ratio. The VID block is also limited to the number of times to be reconfigured. When
this limit is reached, the scan tool will display a message indicating the need to flash the PCM
again to reset the VID block.
Each of the procedures described below use the Worldwide Diagnostic System (WDS).
Reprogramming can be performed by a local Ford dealer for any non Ford facility. There are other
Enhanced Scan Tools that may have reprogramming capabilities available. Refer to the diagnostic
tool manufacturers users manual for details.
Programming the VID Block for a Replacement PCM
A new PCM will contain the latest strategy and calibration level for a particular vehicle. However,
the VID block will be blank and will need programming. There are two procedures available. The
first is an automatic data transfer from the old PCM to the new PCM and the second is manual data
entry into the new PCM.
Automatic data transfer will be performed if the old PCM is capable of communicating. This is done
by the use of a scan tool to retrieve data from the old PCM before removing it from the vehicle. The
stored data can now be downloaded to the new PCM after it has been replaced.
Manual data entry must be performed if the old module is damaged and is incapable of
communicating. Remove and replace the old PCM. You may be instructed to contact the "AS
BUILT" data center for the information needed to manually update the VID block with the scan tool.
Contact the center ONLY if the old PCM cannot be used or the data is corrupt. For Ford L-M
technician's, contact your National Hotline for "AS Built" data. Non Ford technicians, use the Fed
World website at "fedworld.gov". Select Auto Service Information and search for "Calibrations" or
"Vehicle Calibrations" then specify vehicle manufacturer, model name and model year as required.
Making Changes to the VID Block
A PCM which is programmed may require changes to be made to certain VID information to
accommodate vehicle hardware. Refer to PCM/Module Reprogramming on the Scan Tool.
Making Changes to the PCM Calibration
At certain times, the entire EEPROM will need to be completely reprogrammed. This is due to
changes made to the strategy or calibration after production or the need to reset the VID block
because it has reached its limit. Refer to PCM/Module Reprogramming on the Scan Tool.
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and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information > Service and
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Powertrain Control Module: Service and Repair Removal and Installation
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Powertrain Control Module (PCM) electrical connector.
3. Remove the nuts and the PCM cover.
4. Remove the PCM.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers
and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations
Powertrain Control Module Power Relay: Locations
Part (1 Of 2)
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and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 4516
Part (2 Of 2)
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and Control Systems > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 4517
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Absolute Pressure Sensor > Component Information > Description and Operation
Absolute Pressure Sensor: Description and Operation
THERMAL MANIFOLD ABSOLUTE PRESSURE SENSOR
Thermal Manifold Absolute Pressure (TMAP) Sensor
The Thermal Manifold Absolute Pressure Sensor (TMAP) (Figure 41) consists of a Manifold
Absolute Pressure (MAP) sensor and an integrated thermistor. The thermistor part of the sensor is
currently not being used. The MAP part of the sensor measures intake manifold air absolute
pressure. The PCM uses information from the MAP sensor, Throttle Position (TP) sensor, Mass Air
Flow (MAF) sensor, Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CKP)
sensor and Crankshaft Position (CKP) sensor to determine how much exhaust gas is introduced
into the intake manifold.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Nuts And Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 4525
Mass Air Flow Sensor: Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 4526
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 4527
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information >
Specifications > Page 4528
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Loosen the air cleaner outlet tube clamp and position aside.
4. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor, Stud Bolt 19 Nm
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4532
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4533
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 4534
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the CMP sensor electrical connector.
2 Remove the CMP sensor stud bolt.
3 Remove the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Clutch Switch, ECM > Component Information > Diagrams > Page 4538
Clutch Switch: Description and Operation
CLUTCH PEDAL POSITION SWITCH
Typical Clutch Pedal Position (CPP)/Park-Neutral Position (PNP) Switches
The Clutch Pedal Position (CPP) switch (Figure 24) is an input to the PCM indicating the clutch
pedal position and, in some manual transmission applications, both the clutch pedal engagement
position and the gear shift position. The PCM provides a 5-volt reference Vehicle Reference
Voltage (VREF) signal to the CPP switch and/or a Park/Neutral Position (PNP) switch (on the CPP
signal line). If the CPP switch (either or both CPP and PNP switches are closed) is closed,
indicating the clutch pedal is engaged and the shift lever is in the NEUTRAL position, the output
voltage (5 volts) from the PCM is grounded through the signal return line to the PCM, and there is 1
volt or less. One volt or less indicates there is a reduced load on the engine. If the CPP switch (or
PNP switch on vehicle or both CPP and PNP switches open on the vehicle) is open, meaning the
clutch pedal is disengaged (all systems) and the shift lever is not in NEUTRAL position (PNP
switch systems), the input on the CPP signal to the PCM will be approximately 5 volts. Then, the
5-volt signal input at the PCM will indicate a load on the engine. The PCM uses the load
information in mass air flow and fuel calculations.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Engine Coolant Temperature Sensor 15 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 4542
Coolant Temperature Sensor/Switch (For Computer): Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 4543
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 4544
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
REMOVAL
1. Remove the thermostat and housing. For additional information, refer to Cooling System.
2. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the Engine Coolant Temperature (ECT) sensor.
1 Disconnect the connector.
2 Remove the sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolts 10 Nm
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation >
Electronic Engine Controls
Crankshaft Position Sensor: Description and Operation Electronic Engine Controls
The CKP sensor:
^ sends the PCM a signal indicating crankshaft position.
^ is essential for calculating spark timing.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation >
Electronic Engine Controls > Page 4551
Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel)
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Description and Operation >
Page 4552
Crankshaft Position Sensor: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Crankshaft Position (CKP) sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor
has wear tabs that will wear off after several engine revolutions.
^ Be sure sensor wiring is routed away from the battery cable.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature Sensor
Engine Temperature Sensor: Description and Operation Cylinder Head Temperature Sensor
CYLINDER HEAD TEMPERATURE SENSOR
Cylinder Head Temperature (CHT) Sensor
The Cylinder Head Temperature (CHT) sensor (Figure 26) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as
temperature increases, and increases as temperature decreases. The varying resistance affects
the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The Cylinder Head Temperature (CHT) sensor is installed in the aluminum cylinder head and
measures the metal temperature. The CHT sensor can provide complete engine temperature
information and can be used to infer coolant temperature. If the CHT sensor conveys an
overheating condition to the PCM, the PCM would then initiate a fail-safe cooling strategy based on
information from the CHT sensor. A cooling system failure such as low coolant or coolant loss
could cause an overheating condition. As a result, damage to major engine components could
occur. Using both the CHT sensor and fail-safe cooling strategy, the PCM prevents damage by
allowing air cooling of the engine and limp home capability. For additional information, refer to
Powertrain Control Software for Fail-Safe Cooling Strategy details.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Engine Temperature Sensor > Component Information > Description and Operation >
Cylinder Head Temperature Sensor > Page 4557
Engine Temperature Sensor: Description and Operation Engine Coolant Temperature (ECT)
Sensor
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
Engine Coolant Temperature (ECT) Sensor
The Engine Coolant Temperature (ECT) sensor (Figure 27) is a thermistor device in which
resistance changes with temperature. The electrical resistance of a thermistor decreases as the
temperature increases, and increases as the temperature decreases. The varying resistance
affects the voltage drop across the sensor terminals and provides electrical signals to the PCM
corresponding to temperature.
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The ECT measures the temperature of the engine coolant. The sensor is threaded into an engine
coolant passage. The ECT sensor is similar in construction to the IAT sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Description and Operation
Fuel Level Sensor: Description and Operation
The fuel sending unit is a variable resistor made up of a ceramic substrate. It is controlled by the
action of a float arm. When the fuel level is low, resistance in the unit is low. When the fuel level is
high, the resistance is high.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4564
Fuel Tank Pressure Sensor: Service Precautions
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4565
Fuel Tank Pressure Sensor: Description and Operation
Fuel Tank Pressure Sensor
Fuel Tank Pressure (FTP) Sensor
In-Line Fuel Tank Pressure (FTP) Sensor
The Fuel Tank Pressure (FTP) sensor (Figure 97) or inline Fuel Tank Pressure (FTP) sensor
(Figure 98) is used to measure the fuel tank pressure during the EVAP monitor test on vehicles
equipped with the Running Loss-type system. Also, it is used to control excessive fuel tank
pressure by forcing the system to purge.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 4566
Fuel Tank Pressure Sensor: Service and Repair
REMOVAL
1. Remove the fuel tank. For additional information, refer to Fuel Delivery and Air Induction.
2. Remove the fuel tank pressure sensor.
1 Disconnect the electrical connector.
2 Press down and rotate the fuel tank pressure sensor counterclockwise and remove it from the
fuel tank.
CAUTION: The fuel tank pressure sensor must be disengaged from the fuel tank before it can be
removed. Push down and rotate the fuel tank pressure sensor counterclockwise to disengage it
from the fuel tank. Failure to do so can cause damage to the fuel tank pressure sensor or the fuel
tank.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test the evaporative emission system. For additional information, refer to Evaporative
Emission System Leak Test System. See: Emission Control Systems/Evaporative Emissions
System/Testing and Inspection/Component Tests and General Diagnostics/Component
Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emissions repair verification drive cycle. For additional information,
refer to Evaporative Emission Repair Verification Drive Cycle. See: Emission Control
Systems/Evaporative Emissions System/Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation
Intake Air Temperature Sensor: Description and Operation
INTAKE AIR TEMPERATURE SENSOR
Intake Air Temperature (IAT)
Diagram Of Air Flow Through Throttle Body Contacting MAF Sensor Hot and Cold Wire Terminals
The Intake Air Temperature (IAT) sensors (Figure 34) and integrated Mass Air Flow (MAF) type
(Figure 37), are thermistor devices in which resistance changes with temperature. The electrical
resistance of a thermistor decreases as the temperature increases, and increases as the
temperature decreases. The varying resistance affects the voltage drop across the sensor
terminals and provides electrical signals to the PCM corresponding to temperature.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Description and Operation >
Page 4570
Thermistor-type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in a series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The IAT provides air temperature information to the PCM. The PCM uses the air temperature
information as a correction factor in the calculation of fuel spark and MAF.
The IAT sensor provides a quicker temperature change response time than the ECT or CHT
sensor.
Supercharged 5.4L Lightning vehicles use (2) AT sensors. Both sensors operate as above.
However, one is located before the supercharger at the air cleaner for standard OBD II/cold
weather input, while a second sensor Second Intake Air Temperature (IAT2) is located after the
supercharger in the intake manifold. The IAT2 sensor located after the supercharger provides air
temperature information to the PCM to control border-line spark and to help determine intercooler
efficiency.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Bolt 25 Nm
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4574
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4575
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Specifications > Page 4576
Knock Sensor: Service and Repair
REMOVAL
1. Remove the lower in take manifold. For additional information, refer to Engine.
2. Remove the knock sensor.
1 Remove the bolt.
2 Remove the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4581
^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4582
^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4583
The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4584
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4585
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4586
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4587
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4588
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4589
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4590
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4591
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4592
In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4593
4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4594
The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4595
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Technical
Service Bulletins > Page 4596
Heated Oxygen Sensor: Specifications
Heated Oxygen Sensor 41 Nm
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Oxygen Sensor Bank Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Locations >
Oxygen Sensor Bank Locations > Page 4599
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions
Heated Oxygen Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Diagram Information and Instructions > Page 4602
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Diagram Information and Instructions > Page 4603
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram Information and Instructions > Page 4604
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Diagram Information and Instructions > Page 4605
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Diagram Information and Instructions > Page 4606
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Diagram Information and Instructions > Page 4607
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Diagram Information and Instructions > Page 4608
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions > Page 4609
Heated Oxygen Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions > Page 4610
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions > Page 4611
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions > Page 4612
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions > Page 4613
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions > Page 4614
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions > Page 4615
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Diagram Information and Instructions > Page 4616
Heated Oxygen Sensor: Connector Views
Ford does not provide connector views for this vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Diagrams >
Page 4617
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description
and Operation > Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor: Description and Operation Heated Oxygen Sensor (HO2S) Monitor
Heated Oxygen Sensor Monitor
The Heated Oxygen Sensor (HO2S) Monitor is an on-board strategy designed to monitor the HO2S
sensors for a malfunction or deterioration which can affect emissions. The fuel control or upstream
HO2S is checked for proper output voltage and response rate (the time it takes to switch from lean
to rich or rich to lean). Downstream HO2S used for Catalyst Monitor are also monitored for proper
output voltage. The following illustration shows that input is required from the Engine Coolant
Temperature (ECT) or Cylinder Head Temperature (CHT), Intake Air Temperature (IAT), Mass Air
Flow (MAF) and Crankshaft Position (CKP) sensors to activate the HO2S Monitor. The Fuel
System Monitor and Misfire Detection Monitor must also have completed successfully before the
HO2S Monitor is enabled.
1. The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel
ratio of approximately 14.7:1), the HO2S will generate a voltage between zero and 0.45 volt. Rich
of stoichiometric, the HO2S will generate a voltage between 0.45 and 1.0 volt. The HO2S Monitor
evaluates both the upstream (fuel control) and downstream (Catalyst Monitor) HO2S for proper
function.
2. Once the HO2S Monitor is enabled, the upstream HO2S signal voltage amplitude and response
frequency are checked. Excessive voltage is
determined by comparing the HO2S signal voltage to a maximum calibratable threshold voltage. A
fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate. A HO2S
heater circuit fault is determined by turning the heater on and off and looking for a corresponding
change in the Output State Monitor (OSM) and by measuring the current going through the heater
circuit. The HO2S Monitor DTCs can be categorized as follows:
The Diagnostic Trouble Code (DTCs) associated with HO2S lack of switching are DTCs P1130,
P1131, P1132, P1150, P1151 and P1152.
The DTCs associated with HO2S slow response rate are DTCs P0133 and P0153.
The DTCs associated with HO2S signal circuit malfunction are DTCs P0131, P0136, P0148, P0151
and P0156.
The DTCs associated with a HO2S heater circuit malfunction are DTCs P0135, P0141, P0155 and
P0161. The Diagnostic Trouble Code (DTC) associated with the downstream HO2S not running in
on-demand is DTC P1127.
The DTCs associated with swapped HO2S connectors are DTCs P1128 and P1129.
3. The Malfunction Indicator Lamp (MIL) is activated after a fault is detected on two consecutive
drive cycles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description
and Operation > Heated Oxygen Sensor (HO2S) Monitor > Page 4620
Heated Oxygen Sensor: Description and Operation PCM Inputs
HEATED OXYGEN SENSOR
Heated Oxygen Sensor (HO2S)
The Heated Oxygen Sensor (HO2S) (Figure 33) detects the presence of oxygen in the exhaust and
produces a variable voltage according to the amount of oxygen detected. A high concentration of
oxygen (lean air/fuel ratio) in the exhaust produces a low voltage signal less than 0.4 volt. A low
concentration of oxygen (rich air/fuel ratio) produces a high voltage signal greater than 0.6 volt. The
HO2S provides feedback to the PCM indicating air/fuel ratio in order to achieve a near
stoichiometric air/fuel ratio of 14.7:1 during closed loop engine operation. The HO2S generates a
voltage between 0.0 and 1.1 volts.
Embedded with the sensing element is the HO2S heater. The heating element heats the sensor to
temperatures of 800°C (1400°F). At approximately 300°C (600°F) the engine can enter closed loop
operation. The Vehicle Power (VPWR) circuit supplies voltage to the heater and the PCM will
complete the ground when the proper conditions occur. For model year 1998 a new HO2S heater
and heater control system are installed on some vehicles. The high power heater reaches closed
loop fuel control temperatures. The use of this heater requires that the HO2S heater control be duty
cycled, to prevent damage to the heater. The 6 ohm design is not interchangeable with new style
3.3 ohm heater.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description
and Operation > Page 4621
Heated Oxygen Sensor: Service and Repair
EGO Sensor Wrench
SPECIAL SERVICE TOOL(S)
REMOVAL
NOTE: The 5.0L RH is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Raise and support the vehicle. For additional information, refer to Maintenance/Service and
Repair.
2. Remove the bolts and the skid plate. 3. Remove the Three Way Catalytic Converter (TWC). For
additional information, refer to Catalytic Converter.
4. Using the special tool, remove the HO2S.
NOTE: If necessary, lubricate the HO2S with Penetrating and Lock Lubricant E8AZ-19A501-B or
equivalent to assist in removal.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Apply a light coat of High Temperature Nickel Anti-Sieze Lubricant F6AZ-9L494-AA or
equivalent meeting Ford specification ESE-M12A4-A to the threads of the HO2S.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Heated Oxygen Sensor <--> [Oxygen Sensor] > Component Information > Description
and Operation > Page 4622
Syncro Positioning Tool
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4631
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4632
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4633
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4634
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4635
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4641
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4642
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4643
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4644
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall
- Tube Mounted EGR Pressure Sensor Defect > Page 4645
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4650
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4651
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 >
Emissions - MIL ON/Driveability Issues/DTC's Set > Page 4652
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4658
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4659
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions MIL ON/Driveability Issues/DTC's Set > Page 4660
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4661
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR Bolts 8 - 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4662
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4663
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4664
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4665
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the differential pressure feedback EGR electrical connector.
3. Disconnect the differential pressure feedback EGR hoses.
4. Remove the bolts and the differential pressure feedback EGR.
INSTALLATION
1. Fit the differential pressure feedback EGR and loosely install the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical
Service Bulletins > Page 4666
2. Tighten the bolts.
3. Connect the differential pressure feedback EGR hoses.
4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery
ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 4670
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM
Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > PCM
Inputs > Page 4673
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Description and Operation > Page
4674
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Remove the Throttle Position (TP) sensor.
1 Disconnect the TP sensor electrical connector.
2 Remove the sensor.
NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4678
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4679
Digital Transmission Range Sensor: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4680
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4681
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] >
Component Information > Specifications > Page 4682
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor Bolt 98 - 115 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4688
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4689
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4690
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4691
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4692
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4693
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4694
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4695
Vehicle Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4696
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4697
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4698
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4699
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4700
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4701
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 4702
Diagram 64-1
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Vehicle Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
Typical Vehicle Speed Sensor (VSS)
The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that
generates a waveform with a frequency that is proportional to the speed of the vehicle. If the
vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As
the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM
uses the frequency signal generated by the VSS (and other inputs) to control such parameters as
fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch
scheduling.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations
Throttle Position Sensor: Locations
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 4707
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > PCM Inputs > Page 4710
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Description and Operation > Page 4711
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Remove the Throttle Position (TP) sensor.
1 Disconnect the TP sensor electrical connector.
2 Remove the sensor.
NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4715
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4716
Digital Transmission Range Sensor: Diagrams
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4717
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4718
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 4719
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Variable Cam Timing System
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing System
Variable Cam Timing System
Overview
The Variable Cam Timing System allows the exhaust cam to advance and retard at varying engine
speeds. The purpose of this is to reduce exhaust emissions and increase fuel economy. As the
exhaust cam retards in relation to the crankshaft position, residual exhaust gases are left in the
combustion chamber. The residual gases cool the combustion chamber and are inert when mixed
with the incoming fresh charge of fuel and air. This results in better fuel economy and lower
Nitrogen Oxides (NOx) and Hydrocarbons (HG) the engine produces. The Exhaust Gas
Recalculation System (EGR) is unnecessary on the 2.0L (4V) engine due to this feature.
Variable Cam Timing
The Variable Cam Timing (VCT) system consists of the control solenoid, five-tooth pulse ring (4+1)
on exhaust camshaft, Intake Air Temperature (IAT) sensor, Engine Coolant Temperature (ECT)
sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor, Crankshaft Position (CKP)
sensor, Powertrain Control Module (PCM) (Figure 129).
1. The Powertrain Control Module (PCM) receives input signals from the Intake Air Temperature
(IAT) sensor, Engine Coolant
Temperature (ECT) sensor, Camshaft Position (CMP) sensor, Mass Air Flow (MAF) sensor and
Crankshaft Position (CKP) sensor for determining the operating conditions of the engine.
2. The Variable Cam Timing (VCT) system is enabled by the PCM when the proper conditions are
met. The PCM disables the VCT system if
a fault is detected.
3. The PCM calculates relative cam position using the CMP sensor and data from the (4+1) pulse
ring mounted on the exhaust camshaft.
Relative cam position is calculated by measuring the time between the rising edge of Profile
Ignition Pickup (PIP) and the falling edge of Variable Cam Timing (VCT) pulse.
4. The PCM continually calculates a cam position error value based on the difference between the
desired and actual position and a duty
cycle is commanded for the VCT solenoid valve. Engine oil is allowed to flow to the VCT unit.
5. Oil flows to either side of the piston chamber changing a linear motion from the piston to a
rotation motion from the helical mechanism in
the VCT unit. During closed loop the PCM outputs a revised duty cycle to the VCT solenoid valve
to correct for cam position error.
Variable Cam Timing System
HARDWARE
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Variable Cam Timing System > Page 4724
Variable Cam Timing (VCT) Solenoid Valve
Variable Cam Timing (VCT) Solenoid Valve
The VCT solenoid valve (Figure 130) is an integral part of the VCT system. The solenoid valve
controls the flow of engine oil to the variable cam timing unit assembly. As the PCM duty cycles the
solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or retard the cam
timing.
Variable Cam Timing Unit Assembly
Variable Cam Timing (VCT) Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Variable Cam Timing System > Page 4725
in the chamber is designed to hold the camshaft in the minimum overlap position (5 degrees) when
oil pressure is too low to maintain adequate position control. The camshaft is allowed to rotate up
to 30 degrees.
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Actuator >
Component Information > Description and Operation > Variable Cam Timing System > Page 4726
Variable Valve Timing Actuator: Description and Operation Variable Cam Timing (VCT) Unit
Assembly
Variable Cam Timing (VCT) Unit Assembly
Variable Cam Timing Unit Assembly
The variable cam timing unit assembly (Figure 131) is coupled to the camshaft through a helical
spline in the VCT unit chamber. When the flow of oil is shifted from one side of the chamber to the
other, the differential change in oil pressure forces the piston to move linearly along the axis of the
camshaft. This linear motion is translated into rotational camshaft motion through the helical spline
coupling. A spring installed in the chamber is designed to hold the camshaft in the minimum
overlap position (5 degrees) when oil pressure is too low to maintain adequate position control. The
camshaft is allowed to rotate up to 30 degrees.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Variable Valve Timing Solenoid >
Component Information > Description and Operation
Variable Valve Timing Solenoid: Description and Operation
VARIABLE CAM TIMING (VCT) SOLENOID VALVE
Variable Cam Timing (VCT) Solenoid Valve
The Variable Cam Timing (VCT) solenoid valve (Figure 130) is an integral part of the VCT system.
The solenoid valve controls the flow of engine oil to the variable cam timing unit assembly. As the
PCM duty cycles the solenoid valve, oil is allowed to flow to the VCT unit assembly and advance or
retard the cam timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Specifications
Vehicle Speed Sensor: Specifications
Vehicle Speed Sensor Bolt 98 - 115 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Component Information > Diagrams > Diagram Information and Instructions > Page 4735
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4736
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Component Information > Diagrams > Diagram Information and Instructions > Page 4737
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4738
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4739
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4740
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4741
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4742
Vehicle Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Component Information > Diagrams > Diagram Information and Instructions > Page 4743
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Component Information > Diagrams > Diagram Information and Instructions > Page 4744
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4745
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4746
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4747
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 4748
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Component Information > Diagrams > Diagram Information and Instructions > Page 4749
Diagram 64-1
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Component Information > Diagrams > Page 4750
Vehicle Speed Sensor: Description and Operation
VEHICLE SPEED SENSOR
Typical Vehicle Speed Sensor (VSS)
The Vehicle Speed Sensor (VSS) (Figure 45) is a variable reluctance or Hall-effect sensor that
generates a waveform with a frequency that is proportional to the speed of the vehicle. If the
vehicle is moving at a relatively low velocity, the sensor produces a signal with a low frequency. As
the vehicle velocity increases, the sensor generates a signal with a higher frequency. The PCM
uses the frequency signal generated by the VSS (and other inputs) to control such parameters as
fuel injection, ignition control, transmission/transaxle shift scheduling and torque converter clutch
scheduling.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Solenoid >
Component Information > Description and Operation
Air Diverter Solenoid: Description and Operation
AIR BYPASS SOLENOID
Secondary Air Injection Bypass Solenoid
The secondary air injection bypass (AIR bypass) solenoid (Figure 122) is used by the PCM to
control vacuum to the secondary air injection diverter (AIR diverter) valve. The AIR bypass solenoid
is a normally closed solenoid. The AIR bypass solenoid also has a filtered vent feature to permit
vacuum release.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve >
Component Information > Description and Operation
Air Diverter Valve: Description and Operation
AIR DIVERTER VALVE
Air Injection Diverter (AIR Diverter) Valve
The secondary air injection diverter (AIR diverter) valve (Figure 123) is used with the electric AIR
pump to provide on/off control of air to the exhaust manifold and catalytic converter. When the
electric AIR pump is on and vacuum is supplied to the AIR diverter valve, air passes the integral
check valve disk. When the electric AIR pump is off, and vacuum is removed from the AIR diverter
valve, the integral check valve disk is held on the seat and stops air from being drawn into the
exhaust system and prevents the back flow of the exhaust into the Secondary Air Injection System.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump >
Component Information > Description and Operation
Air Injection Pump: Description and Operation
ELECTRIC AIR PUMP
Electric Air Pump
The electric AIR pump (Figure 121) provides pressurized air to the Secondary Air Injection system.
The electric AIR pump functions independently of rpm and is controlled by the PCM. The electric
AIR pump is only used for short periods of time. Delivery of air is dependent on the amount of
system backpressure and system voltage. The inlet system of the AIR pump incorporates a
non-serviceable filter and splash cap which helps to guard against dirt and water.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Pump Relay
> Component Information > Description and Operation
Air Injection Pump Relay: Description and Operation
SOLID STATE RELAY
Solid State Relay
The solid state relay (Figure 124) switches the high current required for operation of the electric
AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Check Valve,
AIR > Component Information > Description and Operation
Vacuum Check Valve: Description and Operation
VACUUM CHECK VALVES
Vacuum Check Valve
A vacuum check valve (Figure 125) blocks air flow in one direction. It allows free air flow in the
other direction. The check side of this valve will hold the highest vacuum registered on the vacuum
side.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis
Technical Service Bulletin # 01-9-7 Date: 010514
Emissions/Engine Controls - Driveability Diagnosis
Article No. 01-9-7
05/14/01
DRIVEABILITY - H025 (HEATED OXYGEN SENSOR), CATALYST, AND FUEL SYSTEM
MONITORS - SERVICE TIPS - OBD II VEHICLES ONLY
FORD: 1994-1997 THUNDERBIRD 1994-2001 MUSTANG 1995-2001 CROWN VICTORIA
1996-1997 PROBE 1996-2000 CONTOUR 1996-2001 ESCORT, TAURUS 2000-2001 FOCUS
1994-1997 F SUPER DUTY, F-250 HD, F-350 1995-2001 ECONOLINE, RANGER, WINDSTAR
1996 BRONCO 1996-1997 AEROSTAR 1996-2001 EXPLORER 1997-2001 EXPEDITION, F-150,
F-250 LD 1999-2001 SUPER DUTY F SERIES 2000-2001 EXCURSION 2001 ESCAPE
LINCOLN: 1995-2001 CONTINENTAL, TOWN CAR 1996-1998 MARK VIII 2000-2001 LS
1998-2001 NAVIGATOR
MERCURY: 1994-1997 COUGAR 1995-2001 GRAND MARQUIS 1996-1999 TRACER 1996-2000
MYSTIQUE 1996-2001 SABLE 1999-2001 COUGAR 1997-2001 MOUNTAINEER
ISSUE This article is intended to be an aide in diagnosing conditions related to Heated Oxygen
Sensor (HO2S), Catalyst, and Fuel System Monitor related Diagnostic Trouble Codes (DTCs).
Additional information is included to assist in diagnosing certain vehicle symptoms. This article is
NOT intended to be a shortcut to the Powertrain Control/Emissions Diagnosis (PC/ED) Workshop
Manual pinpoint tests. The pinpoint tests in the PC/ED Manual should ALWAYS be followed when
diagnosing vehicle conditions.
ACTION Use the following information and Service Tips to assist in the diagnosis of H025,
Catalyst, and Fuel System Monitor related DTCs.
OTHER APPLICABLE ARTICLES: 98-23-10 WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 623000, 690000, 698298
Information
^ A. Description of Terms and Acronyms
^ B. HO2S Location Diagrams
^ C. Heated Oxygen Sensor (HO2S) Monitor
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^ C1. Heated Oxygen Sensor (HO2S) Monitor - Information
^ C2. Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes (DTCs)
^ D. Catalyst Efficiency Monitor
^ D1. Catalyst Efficiency Monitor - Information
^ D2. Catalyst Efficiency Monitor - Diagnostic Trouble Codes (DTCs)
^ E. Fuel System Monitor
^ E1. Fuel System Monitor - Information
^ E2. Fuel System Monitor Diagnostic Trouble Codes (DTCs)
^ F. Diagnostic Service Tips
^ F1. Tips - General
^ F2. Tips Related to Heated Oxygen Sensor (HO2S) Monitor
^ F3. Tips Related to Catalyst Monitor
^ F4. Tips Related to Fuel System Monitor
A. Description of Terms and Acronyms
^ CHT - Cylinder Head Temperature Sensor or PID
^ CKP - Crankshaft Position Sensor or PID
^ DTC - Diagnostic Trouble Code
^ ECT - Engine Coolant Temperature Sensor or PID
^ EGR - Exhaust Gas Recirculation
^ EEC - Electronic Engine Control
^ EVR - EGR Vacuum Regulator
^ FMEM - Failure Mode Effects Management
^ GND - Ground
^ HC - Hydrocarbons
^ HO2S - Heated Oxygen Sensor or PID
^ IAT - Inlet Air Temperature Sensor or PID
^ KAM - Keep Alive Memory
^ KOEO - Key On Engine Off
^ KOER - Key On Engine Running
^ LONGFT - Long Term Fuel Trim
^ MAF - Mass Air Flow Sensor or PID
^ MIL - Malfunction Indicator Lamp ("Check Engine")
^ NGS - New Generation Star Tester (Scan Tool)
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^ OBD II - On-Board Diagnostics II
^ OSM - Output State Monitor
^ PC/ED - Powertrain Control/Emissions Diagnosis
^ PCM - Powertrain Control Module
^ PCV - Positive Crankcase Ventilation
^ PID - Parameter Identification Display
^ RAM - Random Access Memory
^ RPM - Revolutions Per Minute
^ SHRTFT - Short Term Fuel Trim
^ Stoichiometric - 14.7:1 Air/Fuel Ratio (Gasoline Engines)
^ TP - Throttle Position Sensor or PID
^ VMV - Vapor Management Valve
^ VPWR - Vehicle Power (Battery Voltage)
^ VREF - Vehicle Reference Voltage (5 volts)
B. HO2S Location Diagrams
Refer to Figure 1 to better understand the H025 sensor names and locations. Regardless of how
the engine is mounted in the vehicle, conventional or transverse, the HO2S naming convention
stays the same in relationship to engine banks 1 and 2. Bank 1 will always be the bank containing
the # 1 cylinder.
C. Heated Oxygen Sensor (HO2S) Monitor
C1.) Heated Oxygen Sensor (HO2S) Monitor - Information
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The H025 Monitor is an on-board strategy designed to monitor the HO2S sensors for a malfunction
or deterioration that can affect emissions. Under specific conditions, the fuel control or upstream
HO2S sensors (Figures 1 and 3) are checked for proper output voltage and response rate (the time
it takes to switch from lean to rich or rich to lean). Downstream HO2S sensors (Figures 1 and 3)
used for Catalyst Monitor are also monitored for proper output voltage. Input is required from the
ECT or CHT, IAT, MAF, TP and CKP sensors to activate the H025 Monitor. The Fuel System
Monitor and Misfire Detection Monitor must also have completed successfully before the HO2S
Monitor is enabled.
The HO2S sensor senses the oxygen content in the exhaust flow and outputs a voltage between
zero and 1.0 volt. Lean of stoichiometric (air/fuel ratio of approximately 14.7:1 for gasoline
engines), the HO2S will generate a voltage between zero and 0.45 volt. Rich of stoichiometric, the
HO2S will generate a voltage between 0.45 and 1.0 volt.
^ The HO2S Monitor evaluates both the upstream (Fuel Control) and downstream (Catalyst
Monitor) HO2S for proper function.
^ Once the HO2S Monitor is enabled, the upstream H025 signal voltage amplitude and response
frequency are checked. Excessive voltage is determined by comparing the HO2S signal voltage to
a maximum calibratable threshold voltage.
^ A fixed frequency closed loop fuel control routine is executed and the upstream HO2S voltage
amplitude and output response frequency are observed. A sample of the upstream HO2S signal is
evaluated to determine if the sensor is capable of switching or has a slow response rate.
^ An HO2S heater circuit fault is determined by turning the heater on and off and looking for a
corresponding change in the OSM and by measuring the current going through the heater circuit.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The HO2S Monitor DTCs can be categorized as follows:
^ HO2S signal circuit malfunction - P0131, P0136, P0151, P0156
^ HO2S slow response rate - P0133, P0153
^ HO2S heater circuit malfunction - P0135, P0141, P0155, P0161
^ Downstream HO2S not running in on-demand self test - P1127
^ Swapped H025 connectors - P1128 and P1129
^ H025 lack of switching - P1130, P1131, P1132, P1150, P1151, P1152
^ HO2S lack of switching (sensor indicates lean) - P1137
^ H025 lack of switching (sensor indicates rich) - P1138
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Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4779
C2.) Heated Oxygen Sensor (HO2S) Monitor - Diagnostic Trouble Codes
D. Catalyst Efficiency Monitor
D1.) Catalyst Efficiency Monitor - Information
The Federal Test Procedure Catalyst Monitor monitors for deterioration in the catalyst system and
illuminates the MIL when tailpipe emissions exceed the appropriate HC emission thresholds. The
Catalyst Monitor is enabled after the upstream and downstream HO2S sensors have been tested
and verified to be functional. This monitor relies on the front and rear heated oxygen sensors
(HO2S) to infer catalyst efficiency based upon oxygen storage capacity. Under normal closed loop
fuel conditions, high efficiency catalysts have oxygen storage which makes the switching frequency
of the rear HO2S quite slow compared with the frequency of the front HO2S. As catalyst efficiency
deteriorates, its ability to store oxygen declines, and the rear HO2S begins to switch more rapidly,
approaching the frequency of the front sensor. In general, as catalyst efficiency decreases, the
switch ratio increases from a switch ratio of 0 for a low mileage catalyst to a switch ratio of 0.8 or
0.9 for a low efficiency catalyst.
Some vehicles will monitor substantially less than the entire catalyst volume in order to meet the
stringent catalyst monitoring malfunction thresholds. In many cases, only the front, light-off catalyst
is monitored.
Front and rear HO2S switches are counted under specified closed loop fuel conditions. After the
required number of front switches are obtained, a rear-to-front HO2S switch ratio is calculated. The
switch ratio is compared against a threshold value. If the switch ratio is greater than the calibrated
maximum limit, the catalyst has failed. The test entry conditions for the Catalyst Efficiency Monitor
are as follows: ECT or CHT (warmed engine), IAT (not at extreme ambient temperatures), MAF
(greater than minimum engine load), VSS (within vehicle speed window) and TP (at part throttle)
are required.
^ Because an exponentially weighted moving average is used for malfunction determination, up to
six OBD II drive cycles may be required to illuminate the MIL.
NOTE
THE CATALYST MONITOR ON SOME EARLY OBD II VEHICLES (SOME 1994-1996 VEHICLES)
WAS REFERRED TO AS THE "STEADY-STATE CATALYST MONITOR" AS OPPOSED TO THE
"FTP CATALYST MONITOR" (DESCRIBED ABOVE) THAT IS MOST COMMON FOR VEHICLES
BUILT AFTER 1996. BELOW IS A BRIEF DESCRIPTION OF THE STEADY-STATE CATALYST
MONITOR:
The Steady-State Catalyst Monitor performs a 20 second test during steady state rpm and load
conditions. The Monitor transfers closed loop fuel control from the front to the rear 02 sensors. The
Monitor then observes the switching frequency and compares it to a threshold frequency stored in
an rpm/load table. A frequency higher than the maximum calibrated threshold indicates a
malfunction.
The Catalyst Monitor DTCs can be categorized as follows:
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Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4780
^ Catalyst system efficiency below threshold (Bank 1) - P0420
^ Catalyst system efficiency below threshold (Bank 2) - P0430
D2.) Catalyst Efficiency Monitor - Diagnostic Trouble Codes
E. Fuel System Monitor
E1.) Fuel System Monitor - Information
The Fuel System Monitor is an on-board strategy designed to monitor the fuel trim system. The fuel
control system uses fuel trim tables stored in the PCM's KAM to compensate for variability in fuel
system components due to normal wear and aging. Fuel trim tables are based on vehicle speed
and engine load. During closed loop vehicle operation, the fuel trim strategy learns the corrections
needed to correct a "biased" rich or lean fuel system. The correction is stored in the fuel trim tables.
The fuel trim has two means of adapting; a LONGFT and a SHRTFT. LONGFT relies on the fuel
trim tables and SHRTFT refers to the desired air/fuel ratio parameter "LAMBSE". LAMBSE is
calculated by the PCM from HO2S inputs and helps maintain a 14.7:1 air/fuel ratio during closed
loop operation. SHRTFT and LONGFT work together. If the HO2S indicates the engine is running
rich, the PCM will correct the rich condition by moving SHRTFT in the negative range (less fuel to
correct for a rich combustion). If after a certain amount of time SHRTFT is still compensating for a
rich condition, the PCM "learns" this and moves LONGFT into the negative range to compensate
and allows SHRTFT to return to a value near 0%. Input from the ECT or CHT, IAT, and MAF
sensors is required to activate the fuel trim system, which in turn activates the Fuel System
Monitor. Once activated, the Fuel System Monitor looks for the fuel trim tables to reach the
adaptive clip (adaptive limit) and LAMBSE to exceed a calibrated limit. The Fuel System Monitor
will store the appropriate DTC when a fault is detected as described below.
^ The H025 detects the presence of oxygen in the exhaust and provides the PCM with feedback
indicating a rich or lean condition.
^ A correction factor is added to the fuel injector pulsewidth calculation according to the Long and
Short Term Fuel Trims as needed to compensate for variations in the fuel system.
^ When deviation in the parameter LAMBSE increases, air/fuel control suffers and emissions
increase. When LAMBSE exceeds a calibrated limit and the fuel trim table has clipped (reached
adaptive limit), the Fuel System Monitor sets a DTC.
^ The MIL is activated after a fault is detected on two consecutive OBD II drive cycles.
The Fuel System Monitor DTCs can be categorized as follows:
^ Fuel Delivery Error - P0148
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Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4781
^ Lean shift in fuel system operation - P0171 (Bank 1) and P0174 (Bank 2)
^ Rich shift in fuel system operation - P0172 (Bank 1) and P0175 (Bank 2)
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Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4782
E2.) Fuel System Monitor - Diagnostic Trouble Codes
F. Diagnostic Service Tips
1. Always reset KAM after performing a repair:
After performing a repair on a vehicle with the MIL on, and/or DTCs present, always clear KAM.
When a malfunction is present, the PCM adapts (attempts to correct) for this condition. Once the
vehicle has been repaired, if the KAM is not reset, the PCM will once again have to adapt back to
the normal operating conditions. Clearing the KAM will erase what the PCM has learned, so the
PCM will be able to start with "base tables".
2. Always view and record Freeze Frame Data:
Freeze Frame Data can be a valuable asset in duplicating and diagnosing concerns. This data (a
snapshot of certain PID values, recorded at the time the MIL was activated) indicates the manner in
which the vehicle was being driven at the time the fault occurred. This can be especially useful on
intermittent concerns. Freeze Frame Data, in some cases, can also help to isolate possible areas
of concern, as well as ruling out others. Always record (write down) the Freeze Frame Data.
3. Multiple DTCs (with the same meaning):
When multiple (paired) DTCs with the same meaning are set for multiple sensors, it is unlikely that
replacing both HO2S sensors will resolve the concern. In most cases, there will be another issue
that is causing the codes. Examples of multiple (paired) DTCs:
(P0135/P0155), (P0141/P0161), (P1131/P1151), (P1132/P1152).
To further clarify this, see the more detailed scenario as follows:
A vehicle comes in with a MIL On concern. KOEO self test reveals DTCs P0135 and P0155
(HTR-11 and HTR-21 circuit malfunction), with no other DTCs present. The most likely cause of
these DTCs would be something in the heater power circuit that both of these HO2S sensors have
in common (Example: open or shorted heater circuit wiring or splice). It is highly unlikely that
multiple sensors would fail at the same time. When multiple DTCs of this nature are encountered,
reviewing the appropriate wiring diagram(s) can help to isolate possible areas of concern. When
reviewing the wiring diagram, look for things that the affected sensors have in common.
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In this example, the most likely cause of DTCs P0135 and P0155 (with no other DTCs present)
would be a concern with Splice "B" (refer to Figure 2).
NOTE
THIS ILLUSTRATION IS ONLY AN EXAMPLE. SPLICE NAMES "A", "B", AND "C" ARE USED IN
THIS EXAMPLE FOR CONVENIENCE ONLY. ON AN ACTUAL VEHICLE, SPLICE NAMES WILL
DEPEND ON THE CIRCUIT NUMBER FOR THE VEHICLE UNDER REPAIR. NOTE ALSO THAT
THIS FIGURE IS NOT INTENDED TO SHOW ALL SPLICES/CONNECTIONS ON ALL
VEHICLES. OTHER EEC CIRCUITS, NOT SHOWN, MAY ALSO BE SPLICED IN WITH THE
CIRCUITS SHOWN.
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4. View H025 PID data carefully: NGS PIDs for HO2S sensors that do not exist (with certain
exhaust configurations) will show a value of "0" volts (refer to Figures 3 and 4).
In this example, the vehicle (equipped with a 4-cylinder engine) has one upstream and one
downstream HO2S. Notice that the NGS (scan tool) display shows two upstream and two
downstream HO2S PIDs, and that the "unused" HO2S sensor PIDs display "0" volts.
5. H025 sensors measure oxygen in the exhaust, not fuel: The exhaust gas condition reported by
the HO2S sensor is based on the presence of oxygen in the exhaust, not the presence of unburned
fuel.
Example: In the event of an ignition-related misfire, you might expect a rich HO2S reading, due to
the amount of unburned fuel in the exhaust system. However, there is also a large amount of
unburned oxygen, since no combustion took place in the misfiring cylinder. Since the H025 senses
oxygen only, it would report a lean condition in this particular situation.
F2.) Tips Related to Heated Oxygen Sensor (H025) Monitor
1. OBD II Response Rate Monitor: The OBD II
Response Rate Monitor (P0133/P0153) is only run at vehicle speeds between approximately 50-95
km/h (30-60 mph), during steady-state conditions. The test lasts approximately 6 seconds.
Therefore, P0133/P0153 cannot be diagnosed at idle in the repair bay.
2. Do not compare H025 switch rate - Bank-to-Bank or vehicle-to-vehicle: Different H025 switch
rates, from Bank-to-Bank, are considered normal. The H025 switch rate, from one Bank to the
other, should not be compared as a gauge of the H025's ability to switch/react. The PCM is
continuously adjusting spark and fuel in reaction to engine operating conditions (rpm, load, air flow,
throttle angle, etc.). The PCM is also continuously adapting to certain conditions (customer driving
habits, engine and component wear, etc.).
F3.) Tips Related to Catalyst Efficiency Monitor
1. Determining catalyst efficiency/switch ratio:
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Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4785
The upstream H025 sensors will have a high switch frequency, due to normal closed loop fuel
control. With an efficient catalyst, the downstream H025 will have a low switch frequency. The
switch ratio is determined by dividing the number of downstream switches by the number of
upstream switches over a given period of time. As the catalyst ages (or if the catalyst is damaged
or contaminated), the downstream switches will increase. When the downstream switch rate
crosses a threshold value (approximately 0.75 switch ratio), a code is stored (P0420 and/or P0430)
and the MIL illuminates (refer to Figures 5 and 6).
NOTE
IF A CATALYST IS DETERMINED TO HAVE LOW EFFICIENCY AND REQUIRES
REPLACEMENT, REPLACEMENT OF THE DOWNSTREAM H025 SENSORS WILL NOT BE
NECESSARY.
2. Use care in handling H025 sensors: In the event of catalyst replacement, use care in the
handling of H025 sensors to prevent damage or contamination. Do not use power tools in the
removal or installation of sensors. Use a 22mm wrench or crow foot to remove and install H025
sensors; do not use slotted sockets, as these sockets may damage wires. H025 sensors should be
torqued to 41 +/- 5 N.m (30 +/- 4 lb-ft).
3. Do not replace downstream HO2S sensors (H02S12/H02S22) for DTCs P0420 and/or P0430:
When diagnosing a vehicle with a customer concern of MIL On and DTCs P0420/P0430 in
continuous memory, do not replace the downstream HO2S sensors (H02S12/H02S22). Damaged
or malfunctioning downstream HO2S sensors will not cause these DTCs to be set. Always verify
the vehicle concern, then perform the pinpoint diagnostics in the appropriate PC/ED Service
Manual.
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Information > Technical Service Bulletins > Emissions/Engine Controls - Driveability Diagnosis > Page 4786
F4.) Tips Related to the Fuel System Monitor
1. HO2S sensors are not likely to be the cause of adaptive DTCs P0171, P0172, P0174, P0175:
Most warranty-returned HO2S sensors (replaced for these DTCs) are found to function normally.
Additional related DTCs will normally be present if there is a concern with the HO2S sensors. Do
not replace an HO2S sensor unless verified through pinpoint diagnostic tests found in the PC/ED
Service Manual.
2. DTCs P0171, P0172, P0174, and P0175 are not related to downstream H028 sensors: When
diagnosing a vehicle with a MIL On and DTC(s) P0171, P0172, P0174, and/or P0175 in continuous
memory, do not replace the downstream HO2S sensors. These DTCs have no connection to the
downstream HO2S sensor function nor its diagnosis for faults. Always verify the vehicle concern,
then perform the pinpoint diagnostics from the appropriate PC/ED Service Manual.
3. Diagnosing lean conditions and lean DTCs P0171, P0174: Freeze Frame Data can often help to
identify the type of lean condition, even if the fault is intermittent, by indicating how the vehicle was
being driven when the fault occurred. Diagnosis of lean conditions and lean adaptive DTCs can be
difficult, especially if the concern is intermittent. Verifying the concern is extremely important. There
are different types of lean conditions. The ability to identify the type of lean condition causing the
concern can be crucial to a correct diagnosis. When DTCs P0171 and P0174 are both present,
there is a strong likelihood of another concern being present:
a. Vacuum leaks/unmetered air: In this type of condition, the engine may actually run lean of
stoichiometry (14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the
condition. This condition is typically caused by air entering the engine through an abnormal source
(opening), or due to a MAF malfunction. In this situation, the volume of air entering the engine is
actually greater than what the MAF is indicating to the PCM. Vacuum leaks will normally be most
apparent when high manifold vacuum is present, during idle or light throttle. If Freeze Frame Data
indicates that the fault occurred at idle, a check for vacuum leaks/unmetered air when the engine is
cold might be the best starting point.
Examples: Loose, leaking or disconnected vacuum lines, intake manifold gaskets or 0-rings,
throttle body gaskets, brake booster, air inlet tube, stuck/frozen/aftermarket PCV valve, unseated
engine oil dipstick, MAF reading lower than normal, etc.
b. Insufficient fueling: In this type of condition, the engine may actually run lean of stoichiometry
(14.7:1 air/fuel ratio) if the PCM is not able to compensate enough to correct for the condition. This
condition is typically caused by a fuel delivery system concern that restricts or limits the amount of
fuel being delivered to the engine. This condition will normally be most apparent when the engine is
under a heavy load, when a higher volume of fuel is required. If Freeze Frame Data indicates that
the fault occurred under a heavy load, a check of the fuel delivery system (checking fuel pressure
with engine under a load) might be the best starting point.
Examples: Low fuel pressure (fuel pump, fuel filter, fuel leaks, restricted fuel supply lines), fuel
injector concerns, etc.
c. Exhaust system leaks: In this type of condition, the engine may actually be running near
stoichiometry (14.7:1 air/fuel ratio), but the exhaust gas mixture will be lean. This condition is
caused by oxygen-rich air entering the exhaust system through an external source. This condition
will cause the exhaust gas mixture to be lean, even though the actual combustion in the engine
may not be.
Examples: Exhaust system leaks upstream or near HO2S, malfunctioning Secondary Air Injection
system
d. MAF concerns: If a MAF concern is suspected, see TSB 98-23-10.
4. Checking fuel pressure: Check fuel pressure with engine under a load when diagnosing a lean
concern. A partially plugged fuel filter can be difficult to detect and can be easily overlooked if fuel
pressure is only checked at idle. The same is true for other types of fuel supply concerns (e.g., bent
or kinked lines, degraded fuel pump).
At idle, an engine requires only a small volume of fuel. Due to the fact that there is a small volume
of fuel needed at idle, a restriction in the fuel supply line in many cases will not cause the fuel
pressure to be low. When the vehicle is under a load, the engine requires much more fuel than at
idle. Under a load, a restriction in the fuel supply line will prevent the high rate of fuel flow that is
needed to maintain the correct fuel pressure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 4787
Catalytic Converter: Specifications
Three-Way Catalytic Converter Bolts and Nut 25 - 34 ft.lb
Three-Way Catalytic Converter-to-Exhaust Manifold Bolts (4.0L SOHC) 27 - 37 ft.lb
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions
Catalytic Converter: Description and Operation Acronyms and Definitions
2V - L
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
2V: Two Valve engine configuration.
4V: Four Valve engine configuration.
ABS: Anti-lock Brake System.
A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by
cooling and dehydrating the air.
ACC: Air Conditioning Clutch. Indicates status of the A/C clutch.
ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch.
ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel.
ACP: Air Conditioning Head Pressure or A/C cycling switch input state.
ACPSW: Air Conditioning Pressure Switch.
ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module
(PCM) from the ACP switch or sensor.
ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout
control during heavy acceleration.
A/D: Analog-to-Digital. Analog-to-Digital signal conversion.
ADC: See ATDC.
AFCM: Alternative Fuel Control Module.
AIR: Secondary Air Injection.
AIRB: Secondary Air Injection Bypass.
Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system
when the electric air pump is commanded on.
AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System
has been evaluated for OBD (On-Board Diagnostic) II purposes.
Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry.
AIRM: Secondary AIR pump monitor.
Ambient Air Temperature: Temperature of the air surrounding an object.
Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits
of the signal.
ARB: Air Resource Board.
ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by
Speed Control Command Switch (SCCS) inputs.
ASCII: American Standard Code for Information Interchange.
ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke.
Measured in degrees of crankshaft rotation.
AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale,
rather than a digital display.
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Information > Description and Operation > Acronyms and Definitions > Page 4790
AWD: All-Wheel Drive.
BARO: Barometric Pressure.
Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC
solenoid disconnected.
Base Timing: Spark advance in degrees before top dead center of the base engine without any
control from the PCM or ICM.
Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected
directly to the battery. Compare "Vehicle Power (VPWR)."
BAT TEMP: Battery Temperature.
BJB: Battery Junction Box.
BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness.
BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be
hydraulic or electric.
BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the
Brake Pedal Position (BPP) switch.
BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by
applying voltage to the control line.
BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its
stroke. Measured in degrees of crankshaft rotation.
Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to
module and to the DLC.
CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of
pressurized intake air.
CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which
govern fuel economy standards.
CANVNT: Canister Vent Solenoid.
Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine
exhaust emissions.
CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency
Monitor has successfully completed.
CCM: Comprehensive Component Monitor.
CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various
EEC components.
CD A through J: Coil Driver 1 through 10.
Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM)
and safety inspections.
CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case.
CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade.
CHTIL: Cylinder Head Temperature Indicator Lamp.
CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor
thermistor.
CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor.
CKP: Crankshaft Position. Senses the position of the crankshaft.
CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return.
CL: Closed Loop. An operating condition or mode which enables operation based on sensor
feedback.
CMP: Camshaft Position. Indicates camshaft position.
CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4791
CMS: Catalyst Monitor Sensor. Downstream H025.
CMVSS: Canadian Motor Vehicle Safety Standards.
CNG: Compressed Natural Gas.
CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust
emissions.
CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of
fuel.
Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to
increase voltage.
Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the
temperature of external and internal components stabilize.
CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs
generated during Continuous Memory Self-Test.
Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM
whenever the vehicle is operating.
CPP: Clutch Pedal Position. Indicates clutch pedal position.
CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the
clutch pedal is depressed.
CQIS: Common Quality Indicator System.
CSE GND: Case Ground.
CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to
obtain the air/fuel mixture appropriate for closed throttle operation.
CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer.
Data Communications Link: A communication path between various in-vehicle electronic modules.
Accessed by scan tools through the Data Link Connector (DLC).
DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage
measurement of ON time versus the full cycle period, expressed in percent.
DCL: Data Communication Link.
DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a
distributor.
Digital: Controls process information by switching the current or voltage ON and OFF.
DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information.
DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above
the valves.
DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument
cluster.
DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure
transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator
Valve.
DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other
unwanted deposits.
DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while
the vehicle is operating.
DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system.
DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the
On-Board Diagnostic System.
DVOM: Digital Volt-Ohm Meter.
E-85: Fuel containing 85% ethanol alcohol.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4792
EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an
electric air pump.
EAIRM: Electric Secondary Air Pump circuit Monitor.
ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade.
ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor
thermistor.
ECU: Electronic Control Unit. A module that handles the control strategy and monitors system
inputs or outputs.
EEC: Electronic Engine Control system.
EEC-V: Fifth generation EEC system.
EFT: Engine Fuel Temperature.
EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade.
EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor.
EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade.
EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor.
EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into
the combustion chamber.
EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the
monitor is complete.
EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to
operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control.
EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when
energized by the PCM.
EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is
threaded into the bottom of the intake plenum.
EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM.
EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the
EGR valve by varying the duty cycle to the regulator.
EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the
commanded output.
EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists
in the EGRV circuit.
EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module
(ICM) integrated into the PCM.
EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition
System.
EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System.
EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay
operation or noisy generator contacts.
EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new
vehicles perform to design specifications.
EPA: Environmental Protection Agency (U.S. Government).
EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that
requires the electronic storage of information.
ESOF: Electronic Shift-on-the-Fly.
EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere.
EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the
evaporative purge canister.
EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists
for the current commanded state.
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Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4793
EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system
canister from atmospheric pressure during the EVAP OBD II Monitor test.
Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal
which absorbs and holds fuel vapors.
EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap
Canister Purge Solenoid by the PCM.
EVO: Electronic Variable Orifice.
EWP: Electric Water Pump.
Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed
sensor.
FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays
OFF, LOW, or HIGH status.
FC: Fan Control.
FCS: Fuel Control Solenoid.
FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed.
FEAD: Front End Accessory Drive.
FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming
Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming.
FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that
displays the % alcohol content in fuel.
FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating
the inferred alcohol content of fuel.
FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is
reliable or not. Displays a YES or NO.
FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse
width.
FFV: Flexible Fuel Vehicle.
FIFO: First In First Out.
FILO: First In Last Out.
FIM: Fuel Indicator Module.
FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as
a percentage.
FLIV: Fuel Level Input Voltage.
FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle
function in the event of a PCM or EEC component failure.
FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2.
Fuel Pump (Modulated). Fuel pump duty cycle percentage.
FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump.
FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit.
FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults.
Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time.
FRP: Fuel Rail Pressure. Based on FRP V.
FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure
Sensor.
FSC: Fail-Safe Cooling.
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FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or
prevents Natural Gas flow to the fuel rail.
FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or
NO.
FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit.
FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts.
FTP V: Fuel Tank Pressure Voltage. From the FTP transducer.
FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump.
FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update.
FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1
(HEGO1).
FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2
(HEGO2).
FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP.
Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and
pressure from the fuel tank into the Evaporative Emission Control System.
FWD: Front Wheel Drive.
GEM: Generic Electronic Module.
GEN: Generator.
GENF: Generator Output Fault.
GENFDC: Generator Field Control Output.
GFS: Generator field signal monitor.
GND: Ground.
GPM: Grams Per Mile. Also known as Gallons Per Minute.
GPS: Global Positioning Satellite.
Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with
California on-board diagnostics.
GSS: Gear Select Solenoid.
GVW: Gross Vehicle Weight.
Hall Effect: A process where current is passed through a small slice of semi-conductor material and
a magnetic field to produce a small voltage in the semi-conductor.
Hard Fault: A fault currently present in the system.
HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2.
High Compression.
HCF: Hydraulic Cooling Fan.
HCFD: Hydraulic Cooling Fan Drive.
HFC: Hydraulic Cooling Fan.
HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit.
HFP: High Fuel Pump.
HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output
commands with fixed values in response to internal
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PCM malfunctions.
HO: High Output.
HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor.
Provides information on rich or lean exhaust conditions to the PCM.
Hot Soak: Period of time after an engine operates where localized combustion heat dissipates
throughout the engine.
HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the
HO2S sensor.
Hydrogen: Chemical symbol H. Highly flammable gas.
Hz: Hertz. Cycles per second.
IAC: Idle Air Control. Electrical control of throttle bypass air.
IAT: Intake Air Temperature.
IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor.
IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on
supercharged vehicles.
IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor.
IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit
functions.
ICM: Ignition Control Module. The module that controls the ignition system.
IFDM: Integrated Fuel Delivery Module.
IFS: Inertia Fuel Shutoff.
IGN GND: Ignition Ground.
Ignition: System used to provide high voltage spark for internal combustion engines.
IGNKEY(IGKY): Ignition Key status.
IGNSW (IGSW): Ignition Switch Position.
IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the
intake manifold.
IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults.
IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold.
INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output
from the PCM.
Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders.
Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion.
Intercooler: See CAC.
IPATS: Integrated Passive Anti-Theft System.
ISO: international Standards Organization.
KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even
when the vehicle is not operating.
KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM.
Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied
and the engine at rest.
Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the
engine running and the vehicle at rest.
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KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position.
Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the
combustion chamber of an engine.
KOEC: Key On Engine Continuous.
KOEO: Key On Engine off.
KOER: Key On Engine Running.
KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.).
KPH: Kilometers Per Hour.
KS: Knock Sensor. Detects engine knock.
L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts.
LEV: Low Emissions Vehicle.
LFC: Low Fan Control.
LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps.
LIFO: Last In First Out.
LILO: Last In Last Out.
LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM.
LOOP: indicates OPEN or CLOSED loop status.
LPG: Liquefied Petroleum Gas.
LPLR: Low Pressure Low Resistance fuel injector.
M-V
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
M-85: Fuel containing 85% methanol alcohol.
MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine.
MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor.
MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold.
MFC: Medium Fan Control.
MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled.
MFP: Modulated Fuel Pump.
Microprocessor: A digital processor on a chip which perform arithmetic and control logic.
MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related
malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON."
MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the
crankshaft.
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MON: Motor Octane Number.
Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter.
MSOF: Manual Shift-on-the-Fly.
MY: Model Year.
NA: Naturally Aspirated. Engine that is not supercharged or turbocharged.
NAAO: North American Automotive Operations.
NC: Normally Closed.
NG: Natural Gas. A system capable of using natural gas for vehicle operation.
NGS: New Generation STAR (Self-Test Automatic Readout) tester.
NGVM: Natural Gas Vehicle Module.
NO: Norm ally Open.
NO(x): Oxides of Nitrogen. Formed at high combustion temperatures.
NVH: Noise, Vibration, Harshness. A classification of vehicle concerns.
OASIS: On-Line Automotive Service Information System.
OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that
monitors PCM input and output control signals.
On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM.
OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO.
OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane.
OEM: Original Equipment Manufacturer.
OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the
valves.
OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp
ON when engine oil temperature exceeds safe limits.
Open Circuit: A circuit which does not provide a complete path for flow of current.
OL: Open Loop. An operating condition based on instructions not modified by PCM feedback.
O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen
content in exhaust gasses.
OSC: Output State Control.
OSS: Output Shaft Speed.
Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to
ultraviolet radiation.
Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines.
PATS: Passive Anti-Theft System.
PATSIL: Passive Anti-Theft System Indicator Light.
PATSIN: Passive Anti-Theft System Receive Signal.
PATSOUT: Passive Anti-Theft System Transmit Signal.
PATSTRT: Passive Anti-Theft System Starter Relay Control
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PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control)
Processor.
PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase
vapors into the combustion chamber.
PF: Purge Flow. Amount of fuel vapor burned in the engine.
Photochemical: Term describing the action of light on air pollutants which results in creating smog.
PID: Parameter Identifier. Identifies an address in PCM memory which contains operating
information.
Powertrain: Engine and transmission/transaxle components.
Pressure - Absolute: A pressure referenced to a perfect vacuum.
Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude.
Sometimes called Barometric Pressure.
Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer.
Pressure - Differential: The pressure difference between two regions, such as between the intake
manifold and atmospheric pressure.
Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric
pressure.
PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization.
Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP
Sensor).
PPM: Parts Per Million. A measure used in emission analysis.
PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions.
Protocol: A set of rules for the exchange of information on a network.
PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed
information.
PSP: Power Steering Pressure. Indicates the pressure in the power steering system.
PSP V: Power Steering Pressure Input Voltage.
PTEC: Powertrain Electronic Controller.
PTO: Power Take-Off.
PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized.
PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle.
PWR GND: Power Ground. The main ground circuit in the EEC system.
Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and
Continuous Memory Self-Tests. Results are displayed as a series of DTCs.
RABS: Rear Antilock Brake System.
RAM: Random Access Memory. Memory into which information can be written as well as read.
REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate
at high temperatures.
Regulator: Controls the alternator/generator field current to maintain proper battery charge.
Contained within the PCM in smart charging applications.
Relay: An electromechanical device in which connections in one circuit are opened or closed by
changes in another circuit.
REM: Rear Electronic Module.
Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to
improve idle quality and improve emissions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4799
RF: Radio Frequency.
RFI: Radio Frequency Interference.
RFS: Returnless Fuel System.
RM: Relay Module. A module containing two or more relays.
ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered.
RON: Research Octane Number.
Routine: A group of related tasks, such as a series of diagnostic tests.
RPM: Revolutions Per Minute.
RS: Reverse Switch.
RTN: Return. A dedicated sensor ground circuit.
RWD: Rear Wheel Drive.
SAE: Society of Automotive Engineers.
SBS: Supercharger Bypass Solenoid or its signal output from the PCM.
SC: Supercharged or Supercharger.
SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from
the supercharger wastegate actuator to allow for maximum boost.
SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger
Bypass circuit.
SCICP: Supercharger Intercooler Pump Control.
SCICPF: Supercharger Intercooler Pump Control Fault.
SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump.
SCP: Standard Corporate Protocol.
Self- Test: See Quick Test.
Sensor: A device that detects the value or change in a physical quantity, such as temperature,
pressure or flow rate, and converts the data into an electrical signal.
SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is
individually energized and timed relative to its cylinder intake event.
Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic
Interference (EMI).
Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that
intended.
SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input
during closed-loop operation.
SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors.
SIL: Shift Indicator Lamp.
Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output
circuit.
SME: Society of Manufacturing Engineers.
SOF: Shift-On-the-Fly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4800
SOHC: Single Overhead Cam.
Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and
pulled to a central position.
ST: Scan Tool. A device that interfaces with and communicates information on a data link.
Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7
parts of air for every 1 part of fuel.
Switch: A device for making, breaking, or changing the connections in an electrical circuit.
TA: Traction Assist.
TACH: Tachometer.
TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has
an air bypass channel around the throttle plate.
TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel
slippage. 2. Turbocharger.
TDC: Top Dead Center.
Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration.
Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors.
Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees
before (BTDC) or after (ATDC) top dead center of the compression stroke.
TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to
measure intake air temperature.
TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate
information for the PCM.
TP V: Throttle Position Sensor Voltage.
Transducer: A device that receives energy from one medium and transfers it to another. For
example, thermal energy is converted to an electrical signal through a temperature probe.
Transmissions/Transaxles:
NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the
end.
TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns,
procedures, or general service information.
Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles
while running. Also used during engine crank.
Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure.
Variable Reluctance: A process of passing a varying magnetic field through wire windings and
inducing a voltage.
VCT: Variable Camshaft Timing.
VECI: Vehicle Emission Control Information label.
VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced.
Includes information about the year, model, engine, and plant origin of the vehicle.
VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister.
VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a
digital (DVOM) display.
VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare
"Battery Voltage
VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as
a reference by certain sensors.
WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain
other operating conditions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4801
Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger.
WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body.
Zip Tube: Another name for "fresh air duct" or "air inlet duct".
TRANSMISSIONS:
NOTE: The transmission naming convention is as follows:
^ The first character, a number, is the number of forward gears.
^ The second character, either the letter "F" or "R," represents front (transaxle) or rear
(transmission) wheel drive.
^ The next set of characters, a grouping of numbers, represents the design torque capacity of the
transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle).
^ The last character, if used, is one of the following:
^ "E" for electronic shift
^ "N" for non-synchronous shift
^
"S" for synchronous shift
^ "W" for wide ratio
^ 4F27E: Also known as the FN Focus automatic transmission.
^ 4F44E: Formerly known as the CD4E.
^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E.
^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E.
^ 4R44E: Formerly known as A4LD for 3.0L applications.
^ 4R55E: Formerly known as A4LD for 4.0L applications.
^ 4R70W: Formerly known as AOD-E.
^ 4R100: Formerly known as E4OD.
^ 5R44E: Formerly known as A5LD for 3.0L applications.
^ 5R55E: Formerly known as A5LD for 4.0L applications.
^ 5R55N: Lincoln LS automatic transmission.
^ 5R55W: Wide-ratio truck transmission.
^ 4x4L: 4x4 Low.
^ A/T: Automatic Transmission.
^ CCS: Coast Clutch Solenoid.
^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists.
^ EPC: Electronic Pressure Control.
^ EPCV: Electronic Pressure Control Volts.
^ ESS: Electronic Shift Scheduling.
^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E.
^ M5OD: Manual 5-Speed transmission with overdrive (RWD).
^ M/T: Manual Transmission/Transaxle.
^ NPS: Neutral Pressure Switch or its signal input to the PCM.
^ OCS: Overdrive Cancel Switch.
^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft.
^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear
Switch (NGS), and Transmission Switch Neutral (TSN).
^ REVERSE or REV: Transmission Reverse Switch Input.
^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual
transmission/transaxle vehicles.
^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission.
^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and
disengagement of the Torque Converter Clutch.
^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS)
has been activated.
^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled
transmissions.
^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between
an engine and transmission/transaxle.
^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid.
^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same
case. Front-wheel drive applications.
^ Transmission: A device which selectively increases or decreases the ratio of relative rotation
between its input and output shafts. Rear-wheel drive applications.
^ TR: Transmission Range. The range in which the transmission is operating.
^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to
the PCM on the transmission range selector position.
^ TR V: Transmission Range Voltage.
^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft.
^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is
proportional to vehicle speed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4802
Catalytic Converter: Description and Operation Catalyst Efficiency Monitor - Federal Test
Procedure
Catalyst Efficiency Monitor - Federal Test Procedure
The Catalyst Efficiency Monitor uses an oxygen sensor before and after the catalyst to infer the
hydrocarbon efficiency based on oxygen storage capacity of the catalyst. Under normal, close-loop
fuel conditions, high efficiency catalysts have significant oxygen storage. This makes the switching
frequency of the rear Heated Oxygen Sensor (HO2S) very slow and reduces the amplitude of those
switches as compared to the switching frequency and amplitude of the front HO2S. As the catalyst
efficiency deteriorates, its ability to store oxygen declines. The post-catalyst or downstream HO2S
signal begins to switch more rapidly with increasing amplitude, approaching the switching
frequency and amplitude of the pre-catalyst or upstream HO2S.
All applications utilize an FTP-based (Federal Test Procedure) catalyst monitor. This simply means
that the catalyst monitor must run during a standard FTP emission test as opposed to the
20-second steady state catalyst monitor used in 1994 through some 1996 vehicles. Two slightly
different versions of the catalyst monitor are used in the 2001 model year.
Switch Ratio Method (1996 - 2001)
1. In order to assess catalyst oxygen storage, the monitor counts front and rear HO2S switches
during part-throttle, close-loop fuel condition after
the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are
accumulated in up to nine different air mass regions or cells although three air mass regions is
typical. Rear switches are counted in a single cell for all air mass regions. When the required
number of front switches has accumulated in each cell, the total number of rear switches is divided
by the total number of front switches to compute a switch ratio. A switch ratio near 0.0 indicates
high oxygen storage capacity, hence high HC efficiency. A switch ratio near 1.0 indicates low
oxygen storage capacity, hence low HC efficiency. If the actual switch ratio exceeds a calibrated
threshold switch ratio, the catalyst is considered failed.
Inputs from Engine Coolant Temperature (ECT) or Cylinder Head Temperature (CHT) (warm
engine), IAT (not extreme ambient temperatures), Mass Air Flow (MAF) (greater than minimum
engine load), Vehicle Speed Sensor (VSS) (within vehicle speed widow) and Throttle Position (TP)
(at part-throttle) are required to enable the Catalyst Efficiency Monitor.
2. The DTCs associated with this test are Diagnostic Trouble Code (DTC) P0420 (Bank 1) and
P0430 (Bank 2). Because an Exponentially
Weight Moving Average algorithm is use for malfunction determination, up to six driving cycles may
be required to illuminate the Malfunction Indicator Lamp (MIL) during normal customer driving. If
Keep Alive Memory (KAM) is reset, a malfunction will illuminate the MIL in 2 drive cycles.
Index Ratio Method (some 2001 and beyond)
1. In order to assess catalyst oxygen storage, the catalyst monitor counts front HO2S switches
during part-throttle, closed-loop fuel conditions
after the engine is warmed-up and inferred catalyst temperature is within limits. Front switches are
accumulated in up to three different air mass regions or cells. While catalyst monitoring entry
conditions are being met, the front and rear HO2S signal lengths are continually being calculated.
When the required number of front switches has accumulated in each cell, the total signal length of
the rear HO2S is divided by the total signal length of the front HO2S to compute a catalyst index
ratio. An index ratio near 0.0 indicates high oxygen storage capacity, hence high efficiency. A
switch ratio near 1.0 indicates low oxygen storage capacity, hence low HC efficiency. If the actual
index ratio exceeds the threshold index ratio, the catalyst is considered failed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4803
Inputs from ECT or CHT (warm engine), IAT (not extreme ambient temperatures), MAF (greater
than minimum engine load), VSS (within vehicle speed widow) and TP (at part-throttle) are required
to enable the Catalyst Efficiency Monitor.
2. The DTCs associated with this test are DTC P0420 (Bank 1) and P0430 (Bank 2). Because an
Exponentially Weighted Moving Average
algorithm is use for malfunction determination, up to six driving cycles may be required to illuminate
the MIL during normal customer driving. If KAM is reset, a malfunction will illuminate the MIL in 2
drive cycles.
If the catalyst monitor does not complete during a particular driving cycle, the already accumulated
switch/signal data is retained in Keep Alive Memory and is used during the next driving cycle to
allow the catalyst monitor a better opportunity to complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4804
Catalytic Converter: Description and Operation Catalyst and Exhaust Systems
Catalyst and Exhaust System
Overview
The Catalytic Converter and Exhaust Systems (Figure 135) work together to control the release of
harmful engine exhaust emissions into the atmosphere. The engine exhaust gas consists mainly of
Nitrogen (N), Carbon Dioxide (CO2) and Water Vapor (H2O). However, it also contains Carbon
Monoxide (CO), Oxides Of Nitrogen (NOx), Hydrogen (H), and various unburned Hydrocarbons
(HCs). CO, NO(x), and HCs are major air pollutants, and their emission into the atmosphere must
be controlled.
The exhaust system generally consists of an exhaust manifold, front exhaust pipe, upstream
Heated Oxygen Sensor (HO2S), rear exhaust pipe, downstream HO2S, a muffler and an exhaust
tailpipe. The catalytic converter is installed between the front and rear exhaust pipes. Catalytic
converter efficiency is monitored by the On Board Diagnostic (OBD II) system.
Generic Catalyst and Exhaust System
Catalytic Converter
A catalyst is a material that remains unchanged when it initiates and increases the speed of a
chemical reaction. A catalyst will also enable a chemical reaction to occur at a lower temperature.
The concentration of exhaust gas products released to the atmosphere must be controlled. The
catalytic converter assists in this task. It contains a catalyst in the form of a specially treated
honeycomb structure saturated with catalytically active precious metals. As the exhaust gases
come in contact with the catalyst, they are changed into mostly harmless products. The catalyst
initiates and speeds up heat producing chemical reactions of the exhaust gas components so they
are used up as much as possible.
Exhaust System
The purpose of the exhaust system is to convey engine emissions from the exhaust manifold to the
atmosphere. Engine exhaust emissions are directed from the engine exhaust manifold to the
catalytic converter through the front exhaust pipe. An HO2S is mounted on the front exhaust pipe
before the catalyst. The catalytic converter reduces the concentration of Carbon Monoxide (CO),
unburned Hydrocarbons (HCs) and Oxides of Nitrogen (NO) in the exhaust emissions to an
acceptable level. The reduced exhaust emissions are directed from the catalytic converter to a
muffler through the rear exhaust pipe. Another HO2S is mounted on the rear exhaust pipe. Lastly,
the exhaust emissions are directed to the atmosphere through an exhaust tailpipe.
HARDWARE
The downstream HO2S may be located after the light off catalyst or underbody catalyst. The
underbody catalyst may be in-line with the light off catalyst, or the underbody catalyst may be
common to two light off catalysts, forming a "Y" pipe configuration. For an exact configuration of the
catalyst and exhaust system, refer to Exhaust System.
Three Way Catalytic Converter
The Three Way Catalytic (TWC) converter contains either platinum (Pt) and Rhodium (Rh) or
Palladium (Pd) and Rhodium (Rh). The TWC converter catalyzes the oxidation reactions of
unburned HCs and CO and the reduction reaction of NO. The three-way conversion can be best
accomplished by always operating the engine air fuel/ratio at or close to stoichiometry.
Exhaust Manifold/Runners
The exhaust manifold runners collect exhaust gases from engine cylinders. The number of exhaust
manifolds and exhaust manifold runners depends on the engine configuration and number of
cylinders.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Acronyms and Definitions > Page 4805
Exhaust Pipes
Exhaust pipes are usually treated during manufacturing with an anti-corrosive coating agent to
increase the life of the product. The pipes serve as guides for the flow of exhaust gases from the
engine exhaust manifold through the catalytic converter and the muffler.
Upstream Heated and Downstream Heated Oxygen Sensors
The HO2S provide the Powertrain Control Module (PCM) with voltage and frequency information
related to the oxygen content of the exhaust gas.
In addition to providing the PCM with indications of how rich/lean the engine is operating, the
upstream HO2S signal serves as an input to the HO2S monitor. The downstream HO2S signal is
an input to the Catalyst Efficiency monitor.
Muffler
Mufflers are usually treated during manufacturing with an anti-corrosive coating agent to increase
the life of the product. The muffler reduces the level of noise produced by the engine, and it also
reduces the noise produced by exhaust gases as they travel from the catalytic converter to the
atmosphere.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4806
Catalytic Converter: Testing and Inspection
For information regarding diagnosis of this system refer to Computers and Control Systems
Diagnosis.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4807
Catalytic Converter: Service and Repair
Removal
1. Remove the muffler assembly.
2. Disconnect the heated oxygen sensor (HO2S) connectors.
3. Remove the bolts.
4. Remove the bolts and nuts. 5. Remove the LH three way catalytic converter (TWC).
6. Remove the bolts. 7. Twist and remove the RH TWC.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Description and Operation > Page 4808
Installation
1. Note: Before installing the TWCs, install new gaskets.
Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Specifications
Canister Purge Control Valve: Specifications
Canister Purge Valve Bracket Retaining Bolt 25 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Specifications > Page 4813
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Specifications > Page 4814
Canister Purge Control Valve: Service Precautions
WARNING:
^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED
FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE
DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM
THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING,
POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE
PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Specifications > Page 4815
Canister Purge Control Valve: Description and Operation
EVAP Canister Purge Valve
EVAP Canister Purge Valve
EVAP Canister Purge Valve
The EVAP canister purge valve (Figure 95) and (Figure 96) is the part of the Enhanced EVAP
system that is controlled by the PCM. This valve controls the flow of vapors (purging) from the
EVAP canister to the intake manifold during various engine operating modes. The EVAP canister
purge valve is normally closed valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Specifications > Page 4816
Canister Purge Control Valve: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
2. Remove the battery tray. For additional information, refer to Battery.
3. Disconnect the tubes.
1 Disconnect the electrical connector.
2 Disconnect the tubes from the evaporative emission canister purge valve (EVAP canister purge
valve).
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
4. Disconnect the evaporative emission canister purge valve and bracket.
^ Remove the bolt.
5. Remove the evaporative emission canister purge valve.
1 Disconnect the vacuum line from the evaporative emission canister purge valve.
2 Remove the evaporative emission canister purge valve.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Control Valve > Component Information > Specifications > Page 4817
1. To install, reverse the removal procedure.
^ Leak test the evaporative emissions system. For additional information, refer to Evaporative
Emission System Leak Test. See: Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer
to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service and Repair
Evaporative Canister Filter: Service and Repair
REMOVAL
1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For
additional information refer to Battery.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
3. Disconnect the two chassis emissions lines from the evaporative emission tube.
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
4. Remove the evaporative emissions canister bolts.
5. Remove the evaporative emission canister with bracket assembly.
1 Disconnect the canister vent solenoid electrical connector.
2 Remove the EVAP canister with bracket assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Canister Filter > Component Information > Service and Repair > Page 4821
6. Disconnect the canister vent hose.
7. Remove the evaporative emission dust separator.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emission system. For additional information, refer to Evaporative
Emission System Leak Test. See: Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer
to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Specifications
Evaporative Emission Control Canister: Specifications
Evaporative Emissions Canister Bolts 25 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Specifications > Page 4825
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Specifications > Page 4826
Evaporative Emission Control Canister: Service Precautions
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Description and Operation > Description and Operation
Evaporative Emission Control Canister: Description and Operation
The Evaporative Emissions (EVAP) canister:
^ is located under the rear of the vehicle.
^ contains activated carbon.
^ stores fuel vapors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Description and Operation > Description and Operation
> Page 4829
Evaporative Emission Control Canister: Description and Operation Principles of Operation (How
Does It Work ?)
Fuel vapors from the fuel tank are stored in the EVAP canister. When the engine is running, the
vapors are purged from the EVAP canister for combustion. OBD II vehicles sometimes use multiple
canisters, which is dependent upon the size and number of the fuel tanks used on a specific
vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4830
Evaporative Emission Control Canister: Service and Repair
REMOVAL
1. Open the liftgate, lower and remove the spare tire. 2. Disconnect the battery ground cable. For
additional information refer to Battery.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
3. Disconnect the two chassis emissions lines from the evaporative emission tube.
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
4. Remove the evaporative emissions canister bolts.
5. Remove the evaporative emission canister with bracket assembly.
1 Disconnect the canister vent solenoid electrical connector.
2 Remove the EVAP canister with bracket assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Description and Operation > Page 4831
6. Remove the canister vent solenoid and the evaporative emission tube.
1 Disconnect the canister vent solenoid hose from the canister vent solenoid.
2 Remove the canister vent solenoid.
3 Remove the evaporative emission canister purge sleeve.
4 Remove the evaporative emission tube.
7. Remove the evaporative emission canister from the evaporative emission canister bracket.
INSTALLATION
1. To install, reverse removal procedure.
^ Leak test the evaporative emissions system. For additional information, refer to Evaporative
Emission System Leak Test. See: Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer
to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair
NOTE: Lubricate all O-ring seals with MERPOL(R) O-ring Seal Lubricant or equivalent meeting
Ford specification ESE-M99B144-B.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative System Service Port > Component Information > Description and Operation
Evaporative System Service Port: Description and Operation
The Evaporative Emission (EVAP) system test port:
^ is located on the EVAP canister purge outlet tube near the EVAP canister purge valve.
^ is used to connect the Evaporative Emissions System Leak Tester to the EVAP system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative System Service Port > Component Information > Description and Operation > Page 4835
Evaporative System Service Port: Service and Repair
REMOVAL
1. Remove the clip.
2. Disconnect the hoses.
3. Remove the test port assembly.
^ Disconnect the fitting.
^ Remove the test port assembly.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emissions system. For additional information, refer to Evaporative
Emission System Leak Test. See: Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer
to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Solenoid, Evaporative System > Component Information > Description and Operation
Leak Detection Solenoid: Description and Operation
Canister Vent Solenoid
Typical Canister Vent (CV) Solenoid
During the Enhanced EVAP System test monitor, the Canister Vent (CV) solenoid (Figure 99) seals
the EVAP canister from atmospheric pressure. This allows the EVAP canister purge valve to obtain
the target vacuum in the fuel tank during the monitor run.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information
Leak Detection Valve: Technician Safety Information
WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID
IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Service Precautions > Technician Safety Information >
Page 4844
Leak Detection Valve: Vehicle Damage Warnings
CAUTION:
^ The canister vent solenoid must not be energized for more than nine minutes at one time. Once
the canister vent solenoid is energized and de-energized, adequate time must be allowed for the
component to cool adequately. Failure to allow the component to cool may create a false failure in
the diagnostics, causing unnecessary repairs.
^ The evaporative emission system must not be pressurized to more than 3.48 kPa (14
inches/H2O) or damage to the evaporative emission system may occur.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation
Leak Detection Valve: Description and Operation
The canister vent solenoid:
^ is normally open.
^ seals the evaporative emissions system for the Inspection And Maintenance (I/M 240) test and
OBD II leak and pressure tests.
^ is mounted to the evaporative emissions canister bracket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Description and Operation > Description and Operation >
Page 4847
Leak Detection Valve: Description and Operation Principles of Operation (How Does It Work ?)
During the Evaporative Emission Running Loss System Monitor Test, Evaporative Emissions
Repair Verification Drive Cycle, and the Evaporative Emission System leak Test, the canister vent
solenoid is closed to allow either a vacuum to be drawn on the fuel tank or to hold a specified
pressure in the system. The canister vent solenoid is normally open.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Service and Repair > Canister Vent Solenoid
Leak Detection Valve: Service and Repair Canister Vent Solenoid
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID
IS PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
2. Remove the Evaporative Emissions (EVAP) canister. For additional information, refer to
Evaporative Emission Control Canister.
3. Remove the canister vent solenoid.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emission canister and bracket assembly. For additional information,
refer to Evaporative Emission System Leak Test. See: Testing and Inspection/Component Tests
and General Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer
to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Valve, Evaporative System > Component Information > Service and Repair > Canister Vent Solenoid > Page
4850
Leak Detection Valve: Service and Repair Canister Vent Solenoid Closing Procedure
Worldwide Diagnostic System (WDS)
SPECIAL SERVICE TOOL(S)
CAUTION: The canister vent solenoid must not be energized for more than nine minutes at one
time. Once the canister vent solenoid is energized and de-energized, adequate time must be
allowed for the component to cool adequately. Failure to allow the component to cool may create a
false failure in the diagnostics, causing unnecessary repairs.
1. Connect the scan tool and select the output test mode. 2. Select the Fuel Tank Pressure (FTP)
and the volts (V) Parameter Identification (PID) for monitoring. 3. Select the ALL OFF mode. 4.
Close the canister vent solenoid by pushing the START button on the scan tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Locations > Page 4854
Liquid Vapor Separator: Service Precautions
WARNING:
^ THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND CONDENSED
FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE
DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM
THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING,
POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL ARE
PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Locations > Page 4855
Liquid Vapor Separator: Description and Operation
The Fuel Vapor Vent Valve (FVV) assembly is mounted on the top of the fuel tank. It is used to
control the flow of fuel vapors entering the EVAP system. The head portion of the assembly
prevents the fuel tank from overfilling during refueling. The assembly also has a spring float, which
prevents liquid fuel from entering the vapor delivery system under severe handling or vehicle
rollover conditions. In the upright position, the open bottom of the float will lift and shut off the
orifice. Under severe handling conditions, the spring will push the float closed when angles allow
liquid fuel to reach the orifice. In a rollover condition, the weight of the open bottom float and spring
pressure will close the orifice.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid
Vapor Separator, Evaporative System > Component Information > Locations > Page 4856
Liquid Vapor Separator: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
WARNING: THE EVAPORATIVE EMISSIONS SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR LIQUID FUEL
ARE PRESENT IN THE AREA. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN
PERSONAL INJURY.
2. Raise and support the vehicle. For additional information, refer to Maintenance/Service and
Repair.
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN
POSSIBLE PERSONAL INJURY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT
IN PERSONAL INJURY.
3. Drain the fuel tank. For additional information, refer to Fuel Delivery and Air Induction. 4. Lower
the fuel tank. For additional information, refer to Fuel Delivery and Air Induction.
5. Remove the EVAP canister tube from the fuel vapor vent valve.
6. Remove the fuel vapor vent valve.
^ Press down and rotate the fuel vapor vent valve counterclockwise and remove it from the fuel
tank.
INSTALLATION
1. To install, reverse the removal procedure.
^ Leak test the evaporative emissions system. For additional information, refer to Evaporative
Emission System Leak Test. See: Testing and Inspection/Component Tests and General
Diagnostics/Component Tests/Evaporative Emission System Leak Test
^ Carry out the evaporative emission repair verification drive cycle. For additional information, refer
to Evaporative Emission Repair Verification Drive Cycle. See: Service and Repair
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Specifications
EGR Electronic Vacuum Regulator Solenoid: Specifications
EGR Vacuum Regulator Solenoid Nuts 8 - 12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4861
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4862
EGR Electronic Vacuum Regulator Solenoid: Description and Operation
EGR VACUUM REGULATOR SOLENOID
EGR Vacuum Regulator Solenoid
Test Graph
EGR Vacuum Regulator Solenoid Data Chart
The EGR vacuum regulator solenoid (Figure 88) is an electromagnetic device which is used to
regulate the vacuum supply to the EGR valve. The solenoid contains a coil which magnetically
controls the position of a disc to regulate the vacuum. As the duty cycle to the coil increases, the
vacuum signal passed through the solenoid to the EGR valve also increases. Vacuum not directed
to the EGR valve is vented through the solenoid vent to atmosphere. Note that at 0% duty cycle (no
electrical signal applied), the EGR vacuum regulator solenoid allows some vacuum to pass, but not
enough to open the EGR valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Electronic Vacuum Regulator Solenoid > Component Information > Specifications > Page 4863
EGR Electronic Vacuum Regulator Solenoid: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the (A) electrical connector and the (B) vacuum hoses from the Exhaust Gas
Recirculation (EGR) vacuum regulator solenoid.
3. Remove the nuts and the EGR vacuum regulator solenoid.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Specifications
EGR Tube: Specifications
EGR Tube Bracket (Upper) Bolt 7.6 - 10.4 Nm
EGR Tube Fittings (Lower) 34 - 46 Nm
EGR Tube Fittings (Upper) 34 - 46 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Specifications > Page 4867
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Specifications > Page 4868
EGR Tube: Description and Operation
ORIFICE TUBE ASSEMBLY
Orifice Tube Assembly
The orifice tube assembly (Figure 90) is a section of tubing connecting the exhaust system to the
intake manifold. The assembly provides the flow path for the EGR to the intake manifold and also
contains the metering orifice and two pressure pick-up tubes. The internal metering orifice creates
a measurable pressure drop across it as the EGR valve opens and closes. This pressure
differential across the orifice is picked up by the differential pressure feedback EGR sensor which
provides feedback to the PCM.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > Lower
EGR Tube: Service and Repair Lower
REMOVAL
1. Disconnect the EGR pressure transducer hoses.
2. Disconnect the lower EGR tube fittings.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > Lower > Page 4871
EGR Tube: Service and Repair Upper
REMOVAL
1. Remove the EGR valve. 2. Remove the air cleaner outlet tube. For additional information, refer
to Fuel Delivery and Air Induction.
3. Release the tension on the accessory drive belt and position the belt aside.
4. Remove the bolt.
5. Remove the bolts and position the engine accessory bracket forward.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube
> Component Information > Service and Repair > Lower > Page 4872
6. Remove the bolt.
7. Remove the upper EGR tube.
1 Inspect the O-ring seal and install a new O-ring seal if necessary.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications
EGR Valve: Specifications
EGR Valve Bolts 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Specifications > Page 4876
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Differential Pressure Feedback EGR
EGR Valve: Description and Operation Differential Pressure Feedback EGR
EXHAUST GAS RECIRCULATION VALVE
EGR Valve
Test Graph
The EGR valve (Figure 89) in the Differential Pressure Feedback EGR system is a conventional,
vacuum-actuated EGR valve. The valve increases or decreases the flow of exhaust gas
recirculation. As vacuum applied to the EGR valve diaphragm overcomes the spring force, the
valve begins to open. As the vacuum signal weakens, at 5.4 kPa (1.6 in-Hg) or less, the spring
force closes the valve. The EGR valve is fully open at about 15 kPa (4.5 in-Hg).
Since EGR flow requirement varies greatly, providing service specifications on flow rate is
impractical. The on-board diagnostic system monitors the EGR valve function and triggers a
Diagnostic Trouble Code if the test criteria is not met. The EGR valve flow rate is not measured
directly as part of the field diagnostic procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Differential Pressure Feedback EGR > Page 4879
EGR Valve: Description and Operation Electric Motor EGR System (EEGR)
ELECTRIC EGR VALVE
Electric EGR Motor/Valve Assembly
Electric EGR
The electric EGR valve (Figure 92) and (Figure 93) is a water cooled motor/valve assembly. The
motor is commanded to move in 52 discrete steps as it acts directly on the the EGR valve. The
position of the valve determines the rate of EGR. The built in spring works to close the valve
(against the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Differential Pressure Feedback EGR > Page 4880
motor opening force).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve
> Component Information > Description and Operation > Page 4881
EGR Valve: Service and Repair
REMOVAL
1. Disconnect the EGR valve vacuum connection.
2. Disconnect the EGR tube upper fitting.
3. Remove the EGR valve bolts and the EGR valve.
INSTALLATION
1. To install, reverse the removal procedure.
^ Carefully clean all sealing surfaces and install a new EGR valve gasket.
NOTE: The EGR valve sealing surfaces are soft metals.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4890
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4891
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4892
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4893
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Recalls: > 02M01S6 > Aug > 04
> Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4894
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4900
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4901
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4902
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4903
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect >
Page 4904
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4909
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4910
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4911
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4917
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4918
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability Issues/DTC's Set > Page
4919
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4920
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR Bolts 8 - 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4921
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4922
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4923
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4924
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the differential pressure feedback EGR electrical connector.
3. Disconnect the differential pressure feedback EGR hoses.
4. Remove the bolts and the differential pressure feedback EGR.
INSTALLATION
1. Fit the differential pressure feedback EGR and loosely install the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure
Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > Page 4925
2. Tighten the bolts.
3. Connect the differential pressure feedback EGR hoses.
4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery
ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Service Precautions
Positive Crankcase Ventilation: Service Precautions
CAUTION: Do not remove the PCV system from the engine. Removal of the PCV system will
adversely affect the fuel economy and engine ventilation and result in shorter engine life.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Description and Operation > Acronyms and Definitions
Positive Crankcase Ventilation: Description and Operation Acronyms and Definitions
2V - L
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
2V: Two Valve engine configuration.
4V: Four Valve engine configuration.
ABS: Anti-lock Brake System.
A/C: Air Conditioning. A vehicle accessory system that modifies the passenger compartment air by
cooling and dehydrating the air.
ACC: Air Conditioning Clutch. Indicates status of the A/C clutch.
ACCS: Air Conditioning Cycling Switch. Indicates status of the A/C cycling switch.
ACD: Air Conditioning Demand. A signal input to the PCM from the Air Conditioning control panel.
ACP: Air Conditioning Head Pressure or A/C cycling switch input state.
ACPSW: Air Conditioning Pressure Switch.
ACPV: Air Conditioning Head Pressure Volts. A voltage input to the Powertrain Control Module
(PCM) from the ACP switch or sensor.
ACR: Air Conditioning Relay. Commanded output controlled by the PCM and acts as an A/C cutout
control during heavy acceleration.
A/D: Analog-to-Digital. Analog-to-Digital signal conversion.
ADC: See ATDC.
AFCM: Alternative Fuel Control Module.
AIR: Secondary Air Injection.
AIRB: Secondary Air Injection Bypass.
Air Diverter: Air Diverter Valve. Part of the EAIR system. Diverts fresh air to the exhaust system
when the electric air pump is commanded on.
AIR EVAL: Air System Evaluated. Displays a YES or NO status indicating whether the Air System
has been evaluated for OBD (On-Board Diagnostic) II purposes.
Air/Fuel Ratio: Air to fuel mixture ratio. An air/fuel mixture that is 14.7:1 is also called stoichiometry.
AIRM: Secondary AIR pump monitor.
Ambient Air Temperature: Temperature of the air surrounding an object.
Analog (Electrical/Electronic): An electrical signal that can obtain any value within the voltage limits
of the signal.
ARB: Air Resource Board.
ARPMIDES: Ancillary RPM Desired. RPM required to maintain the vehicle speed commanded by
Speed Control Command Switch (SCCS) inputs.
ASCII: American Standard Code for Information Interchange.
ATDC: After Top Dead Center. The location of the piston after it has reached the top of its stroke.
Measured in degrees of crankshaft rotation.
AVOM: Analog Volt-Ohm Multimeter. Readings are indicated by a sweep hand on a printed scale,
rather than a digital display.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Description and Operation > Acronyms and Definitions > Page 4931
AWD: All-Wheel Drive.
BARO: Barometric Pressure.
Base Idle: Idle rpm determined by the throttle lever hardset on the throttle body with the IAC
solenoid disconnected.
Base Timing: Spark advance in degrees before top dead center of the base engine without any
control from the PCM or ICM.
Battery Positive Voltage (B+): The positive (+) voltage from the battery or any circuit connected
directly to the battery. Compare "Vehicle Power (VPWR)."
BAT TEMP: Battery Temperature.
BJB: Battery Junction Box.
BOB: Breakout Box. A test device which connects in series to the PCM and PCM harness.
BPA: Brake Pedal Applied switch. Typically located on the braking system master cylinder. Can be
hydraulic or electric.
BPP: Brake Pedal Position. Indicates the position of the brake pedal, based on input from the
Brake Pedal Position (BPP) switch.
BRAKE LMP or BRKL: Brake Warning Lamp Status. Activates the Brake Warning Lamp by
applying voltage to the control line.
BTDC: Before Top Dead Center. The location of the piston before it has reached the top of its
stroke. Measured in degrees of crankshaft rotation.
Bus + or Bus -: Multiplex circuits that carry Standard Corporate Protocol (SCP) data from module to
module and to the DLC.
CAC: Charge Air Cooler. Formerly known as Intercooler. A device which lowers the temperature of
pressurized intake air.
CAFE: Corporate Average Fuel Economy. A set of federal requirements and regulations which
govern fuel economy standards.
CANVNT: Canister Vent Solenoid.
Catalyst: Catalytic converter. An in-line exhaust system device used to reduce the level of engine
exhaust emissions.
CAT EVAL: Catalyst System Evaluated. This item indicates YES when the Catalyst Efficiency
Monitor has successfully completed.
CCM: Comprehensive Component Monitor.
CCRM: Constant Control Relay Module. A relay module that provides ON-OFF control of various
EEC components.
CD A through J: Coil Driver 1 through 10.
Centralized Testing Facility: State government operation. Provides Inspection/Maintenance (IM)
and safety inspections.
CGND or CSE GND: Case Ground. Provides a ground source for the PCM or ECU case.
CHT: Cylinder Head Temperature. Units are displayed in either degrees Fahrenheit or Centigrade.
CHTIL: Cylinder Head Temperature Indicator Lamp.
CHTV: Cylinder Head Temperature Voltage. The actual voltage drop across the CHT sensor
thermistor.
CID: Cylinder Identification. PCM input signal from Camshaft Position Sensor.
CKP: Crankshaft Position. Senses the position of the crankshaft.
CKP+, CKP-: CKP+ is the Crankshaft Position (CKP) sensor signal wire. CKP - is the signal return.
CL: Closed Loop. An operating condition or mode which enables operation based on sensor
feedback.
CMP: Camshaft Position. Indicates camshaft position.
CMPFM: Camshaft Position Failure Mode. Indicates when the PCM identifies a CID/CMP fault.
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CMS: Catalyst Monitor Sensor. Downstream H025.
CMVSS: Canadian Motor Vehicle Safety Standards.
CNG: Compressed Natural Gas.
CO: Carbon Monoxide. A colorless, odorless and toxic gas that is a component of auto exhaust
emissions.
CO(2): Carbon Dioxide. A colorless, odorless gas that is a normal by-product of the combustion of
fuel.
Coil: A device consisting of windings around an iron core. In a spark ignition system, designed to
increase voltage.
Cold Soak: Time given to a vehicle to sit at a low temperature (typically below 68°F / 20°C) until the
temperature of external and internal components stabilize.
CONT: Continuous Memory. The portion of KAM (Keep Alive Memory) used to store DTCs
generated during Continuous Memory Self-Test.
Continuous Memory Self- Test: A continuous test of the EEC system conducted by the PCM
whenever the vehicle is operating.
CPP: Clutch Pedal Position. Indicates clutch pedal position.
CPP Switch: Clutch Pedal Position Switch. Located on the clutch pedal and detects when the
clutch pedal is depressed.
CQIS: Common Quality Indicator System.
CSE GND: Case Ground.
CT: Closed Throttle Mode. A mode when the PCM varies the pulse width of the fuel injectors to
obtain the air/fuel mixture appropriate for closed throttle operation.
CTO: Clean Tach Output. Signal used to drive the instrument panel tachometer.
Data Communications Link: A communication path between various in-vehicle electronic modules.
Accessed by scan tools through the Data Link Connector (DLC).
DC: 1. Direct Current. Electric current flowing in one direction. 2. Duty Cycle. The voltage
measurement of ON time versus the full cycle period, expressed in percent.
DCL: Data Communication Link.
DI: Distributor Ignition. A system in which the ignition coil secondary circuit is sequenced by a
distributor.
Digital: Controls process information by switching the current or voltage ON and OFF.
DLC: Data Link Connector. J1962 connector providing access to vehicle diagnostic information.
DOHC: Dual Overhead Cam. An engine configuration that uses two camshafts positioned above
the valves.
DOL: Data Output Line. A circuit that sends certain information from the PCM to the instrument
cluster.
DPFEGR: Differential Pressure Feedback Exhaust Gas Recirculation. System that uses a pressure
transducer to control the operation of the Exhaust Gas Recirculation (EGR) Vacuum Regulator
Valve.
DRI: Deposit Resistant Injector. A fuel injector designed to prevent build-up of carbon and other
unwanted deposits.
DRL: Daytime Running Lamps. A system that keeps the vehicle running lamps on at all times while
the vehicle is operating.
DTM: Diagnostic Test Mode. A level of capability in an On-Board Diagnostic (OBD) system.
DTC: Diagnostic Trouble Code. An alpha/numeric identifier for a fault condition identified by the
On-Board Diagnostic System.
DVOM: Digital Volt-Ohm Meter.
E-85: Fuel containing 85% ethanol alcohol.
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EAIR: Electric Secondary Air Injection. A pump-driven system for providing secondary air using an
electric air pump.
EAIRM: Electric Secondary Air Pump circuit Monitor.
ECT: Engine Coolant Temperature. Displayed in either Fahrenheit or Centigrade.
ECTV: Engine Coolant Temperature Voltage. The actual voltage drop across the ECT sensor
thermistor.
ECU: Electronic Control Unit. A module that handles the control strategy and monitors system
inputs or outputs.
EEC: Electronic Engine Control system.
EEC-V: Fifth generation EEC system.
EFT: Engine Fuel Temperature.
EFTA: Bank 1 input. EFTA is displayed in either Fahrenheit or Centigrade.
EFTAV: Voltage drop across the EFTA (Bank 1) sensor thermistor.
EFTB: Bank 2 input. EFTB is displayed in either Fahrenheit or Centigrade.
EFTBV: Voltage drop across the EFTB (Bank 2) sensor thermistor.
EGR: Exhaust Gas Recirculation. A process in which a small amount of exhaust gas is routed into
the combustion chamber.
EGR EVAL: Exhaust Gas Recirculation System Evaluated. EGR EVAL will display YES when the
monitor is complete.
EGRMDSD: Electric Exhaust Gas Recirculation Motor Desired position. The PID name used to
operate the Electric Exhaust Gas Recirculation (EEGR) valve with scan tool's output state control.
EGRS: EGR Shutoff. A normally closed solenoid that applies vacuum to the EGR valve when
energized by the PCM.
EGRT: Exhaust Gas Recirculation Valve Temperature Sensor. A temperature sensor that is
threaded into the bottom of the intake plenum.
EGR Vacuum Regulator: Controls vacuum to the EGR valve by a duty cycle signal from the PCM.
EGRVR: Exhaust Gas Recirculation Vacuum Regulator. Solenoid which varies the vacuum to the
EGR valve by varying the duty cycle to the regulator.
EGRVRA: Exhaust Gas Recirculation Vacuum Regulator Actual (volt). The actual state of the
commanded output.
EGRVRF: Exhaust Gas Recirculation Vacuum Regulator Fault. Represents whether a fault exists
in the EGRV circuit.
EI: Integrated Electronic Ignition. An Electronic Ignition system that has the Ignition Control Module
(ICM) integrated into the PCM.
EI-HDR: Electronic Ignition, High Data Rate. Formerly known as Electronic Distributorless Ignition
System.
EI-LDR: Electronic Ignition, Low Data Rate. Formerly known as Distributorless Ignition System.
EMI: Electromagnetic Interference. Usually caused by ignition voltage spikes, solenoids, relay
operation or noisy generator contacts.
EOL: End Of Line. A system designed specifically for use at assembly plants to make sure all new
vehicles perform to design specifications.
EPA: Environmental Protection Agency (U.S. Government).
EPROM: Erasable Programmable Read-Only Memory. An electronic component in the PCM that
requires the electronic storage of information.
ESOF: Electronic Shift-on-the-Fly.
EVAP: Evaporative Emissions. A system to prevent fuel vapor from escaping into the atmosphere.
EVAPCP: Evaporative Canister Purge Solenoid. Controls a solenoid which allows venting of the
evaporative purge canister.
EVAPCPF: Evaporative Canister Purge Solenoid Fault. Identifies whether an electrical fault exists
for the current commanded state.
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EVAPCV: Evaporative Canister Vent Solenoid. Controls a solenoid which seals the EVAP system
canister from atmospheric pressure during the EVAP OBD II Monitor test.
Evaporative Emissions Canister: An evaporative emission canister, containing activated charcoal
which absorbs and holds fuel vapors.
EVAPPDC: Evaporative Canister Purge Duty Cycle. The duty cycle commanded to the Evap
Canister Purge Solenoid by the PCM.
EVO: Electronic Variable Orifice.
EWP: Electric Water Pump.
Exciter Ring: A toothed or notched iron or steel disk, which is the moveable part of a wheel speed
sensor.
FAN: Fan Speed. Used in conjunction with vehicles having multiple fan speed control. Displays
OFF, LOW, or HIGH status.
FC: Fan Control.
FCS: Fuel Control Solenoid.
FCIL: Fuel Cap Off Indicator Lamp. Indicates that the fuel filler cap was not properly installed.
FEAD: Front End Accessory Drive.
FEPS: Flash Electrically Erasable Programmable Read Only Memory (EEPROM) Programming
Signal. 18 volt DC signal sent by the scan tool to initiate PCM reprogramming.
FF: 1. Flexible Fuel. A system capable of using a variety of fuels for vehicle operation. 2. A PID that
displays the % alcohol content in fuel.
FFLRN: Flex Fuel Learned. Displays when the PCM's Flex Fuel strategy has completed calculating
the inferred alcohol content of fuel.
FFFM: Flexible Fuel Failure Mode. Indicates whether the current Flex Fuel Sensor reading (FF) is
reliable or not. Displays a YES or NO.
FFTEMP: Flexible Fuel Sensor - Temperature. Alcohol concentration derived from the signal pulse
width.
FFV: Flexible Fuel Vehicle.
FIFO: First In First Out.
FILO: First In Last Out.
FIM: Fuel Indicator Module.
FLI: Fuel Level Input. Used by the Evap monitor to calculate fuel tank vapor volume. Displayed as
a percentage.
FLIV: Fuel Level Input Voltage.
FMEM: Failure Mode Effects Management. Operating strategy that maintains limited vehicle
function in the event of a PCM or EEC component failure.
FP:1. Fuel Pump. Indicates whether the pump has been commanded ON or OFF by the PCM. 2.
Fuel Pump (Modulated). Fuel pump duty cycle percentage.
FPDM: Fuel Pump Driver Module. A module that controls the electric fuel pump.
FPF: Fuel Pump Fault. Identifies whether a fault exists in the FP circuit.
FPM: Fuel Pump Monitor. Monitors the Fuel Pump I circuits for faults.
Freeze Frame: A block of memory containing the vehicle operating conditions at a specific time.
FRP: Fuel Rail Pressure. Based on FRP V.
FRP V: Fuel Rail Pressure Voltage. A voltage input to the PCM from the Fuel Rail Pressure
Sensor.
FSC: Fail-Safe Cooling.
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FSV: Fuel Shut-off Valve. A component of Natural Gas Vehicles. This valve either allows or
prevents Natural Gas flow to the fuel rail.
FSVF: Fuel Shut-Off Valve Fault. Indicates if there is a fault in the FSV circuit. Displayed as YES or
NO.
FSVM: Fuel Shut-off Valve Monitor. Monitors operation of the Fuel Shut-Off Valve / circuit.
FTP: Fuel Tank Pressure. Displayed as inches of water, kPa, or volts.
FTP V: Fuel Tank Pressure Voltage. From the FTP transducer.
FUEL PR: Fuel Pressure. Measurement of the force of the fuel delivered via the fuel pump.
FUELPW: Fuel Pulse Width. Displays the commanded pulse width at time of last data update.
FUELPW1: Fuel Injector Pulse Width #1. Corresponds to injectors normally affected by O2S1
(HEGO1).
FUELPW2: Fuel Injector Pulse Width #2. Corresponds to injectors normally affected by O2S2
(HEGO2).
FUELSYS: Fuel System Status (OPEN/CLOSED Loop). Formerly known as LOOP.
Fuel Tank Vapor Valve: A valve mounted in the top of the fuel tank that vents excess vapor and
pressure from the fuel tank into the Evaporative Emission Control System.
FWD: Front Wheel Drive.
GEM: Generic Electronic Module.
GEN: Generator.
GENF: Generator Output Fault.
GENFDC: Generator Field Control Output.
GFS: Generator field signal monitor.
GND: Ground.
GPM: Grams Per Mile. Also known as Gallons Per Minute.
GPS: Global Positioning Satellite.
Green State Vehicle: Formally known as California Emissions. A vehicle that is equipped with
California on-board diagnostics.
GSS: Gear Select Solenoid.
GVW: Gross Vehicle Weight.
Hall Effect: A process where current is passed through a small slice of semi-conductor material and
a magnetic field to produce a small voltage in the semi-conductor.
Hard Fault: A fault currently present in the system.
HC: 1. Hydrocarbon. A by-product of combustion and a component of auto exhaust emissions. 2.
High Compression.
HCF: Hydraulic Cooling Fan.
HCFD: Hydraulic Cooling Fan Drive.
HFC: Hydraulic Cooling Fan.
HFCF: High Fan Control Fault. Identifies if there is a fault in the HFC circuit.
HFP: High Fuel Pump.
HLOS: Hardware Limited Operating Strategy. A mode of operation where the PCM replaces output
commands with fixed values in response to internal
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PCM malfunctions.
HO: High Output.
HO2S: Heated Oxygen Sensor. Formerly known as Heated Exhaust Gas Oxygen (HEGO) Sensor.
Provides information on rich or lean exhaust conditions to the PCM.
Hot Soak: Period of time after an engine operates where localized combustion heat dissipates
throughout the engine.
HTR, HTR11, HTR12, HTR21 H1R22, HTRX1, HTRX2: HO2S Heater. Heater element for the
HO2S sensor.
Hydrogen: Chemical symbol H. Highly flammable gas.
Hz: Hertz. Cycles per second.
IAC: Idle Air Control. Electrical control of throttle bypass air.
IAT: Intake Air Temperature.
IATV: Intake Air Temperature Voltage. Actual voltage drop across the IAT sensor.
IAT2: Intake Air Temperature 2. Displayed in either Fahrenheit or Centigrade. Used on
supercharged vehicles.
IAT2V: Intake Air Temperature 2 Voltage. Actual voltage drop across the IATV2 sensor.
IC: Integrated Circuit. A small Semi-Conductor device capable of doing many separate circuit
functions.
ICM: Ignition Control Module. The module that controls the ignition system.
IFDM: Integrated Fuel Delivery Module.
IFS: Inertia Fuel Shutoff.
IGN GND: Ignition Ground.
Ignition: System used to provide high voltage spark for internal combustion engines.
IGNKEY(IGKY): Ignition Key status.
IGNSW (IGSW): Ignition Switch Position.
IMRC: Intake Manifold Runner Control. Controls airflow through the high-speed runners in the
intake manifold.
IMRCM: Intake Manifold Runner Control Monitor. Monitors the IMRC / circuits for faults.
IMTV: Intake Manifold Tuning Valve. Controls airflow through runners in a split intake manifold.
INJ1, INJ2, INJ3, INJ4, INJ5, INJ6, INJ7, INJ8, INJ9, INJ1O: lnjector number or its signal output
from the PCM.
Injector: A device for delivering metered pressurized fuel to the intake system or the cylinders.
Intake Air: Air drawn through a filter and distributed to each cylinder for use in combustion.
Intercooler: See CAC.
IPATS: Integrated Passive Anti-Theft System.
ISO: international Standards Organization.
KAM: Keep Alive Memory. A portion of the memory within the PCM that must have power even
when the vehicle is not operating.
KAPWR: Keep Alive Power. Dedicated, unswitched power circuit that maintains KAM.
Key On Engine Off Self- Test: A test of the EEC system conducted by the PCM with power applied
and the engine at rest.
Key On Engine Running Self- Test: A test of the EEC system conducted by the PCM with the
engine running and the vehicle at rest.
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KEYPWR: Key Power. Battery voltage supplied when the ignition key is in the ON position.
Knock: The sharp metallic sound produced when two combustion pressure fronts collide in the
combustion chamber of an engine.
KOEC: Key On Engine Continuous.
KOEO: Key On Engine off.
KOER: Key On Engine Running.
KPA: Kilopascal. Unit of pressure. 3.386 kPa = 1 inch of mercury (Hg.).
KPH: Kilometers Per Hour.
KS: Knock Sensor. Detects engine knock.
L: Liters. The unit of volume in the metric measuring system. One liter equals 1.06 quarts.
LEV: Low Emissions Vehicle.
LFC: Low Fan Control.
LFP: Low Fuel Pump. Reduced operating speed for multi-speed fuel pumps.
LIFO: Last In First Out.
LILO: Last In Last Out.
LONGFT1, LONGFT2: Long-Term Fuel Trim. Fuel flow adjustment determined by the PCM.
LOOP: indicates OPEN or CLOSED loop status.
LPG: Liquefied Petroleum Gas.
LPLR: Low Pressure Low Resistance fuel injector.
M-V
ACRONYMS AND DEFINITIONS
NOTE: This Acronyms and Definitions listing contains technical terms applicable to Ford Motor
Company products. It is not intended to be an all-inclusive dictionary of components and their
functions. If a detailed description of a particular system or component is desired, refer to the
applicable Vehicle System for the specific vehicle being serviced.
M-85: Fuel containing 85% methanol alcohol.
MAF: Mass Air Flow. Used to measure the mass (weight) of the air entering the engine.
MAF RTN: Mass Air Flow Return. A return circuit for the MAF sensor.
MAP: Manifold Absolute Pressure. The internal pressure of the intake manifold.
MFC: Medium Fan Control.
MFI: Multiport Fuel Injection. A fuel-delivery system in which each cylinder is individually fueled.
MFP: Modulated Fuel Pump.
Microprocessor: A digital processor on a chip which perform arithmetic and control logic.
MIL: Malfunction Indicator Lamp. An indicator lamp alerting the driver of an emission related
malfunction. May also read "CHECK ENGINE" or "SERVICE ENGINE SOON."
MISF: Misfire. Any event in the cylinder that causes a sudden change in acceleration of the
crankshaft.
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MON: Motor Octane Number.
Monolithic Substrate: The ceramic honeycomb structure used in the catalytic converter.
MSOF: Manual Shift-on-the-Fly.
MY: Model Year.
NA: Naturally Aspirated. Engine that is not supercharged or turbocharged.
NAAO: North American Automotive Operations.
NC: Normally Closed.
NG: Natural Gas. A system capable of using natural gas for vehicle operation.
NGS: New Generation STAR (Self-Test Automatic Readout) tester.
NGVM: Natural Gas Vehicle Module.
NO: Norm ally Open.
NO(x): Oxides of Nitrogen. Formed at high combustion temperatures.
NVH: Noise, Vibration, Harshness. A classification of vehicle concerns.
OASIS: On-Line Automotive Service Information System.
OBD, OBD-II: On-Board Diagnostics, On-Board Diagnostics Second Generation. A system that
monitors PCM input and output control signals.
On Demand Test: Technician initiated "KOEO" and "KOER" tests performed by the PCM.
OC: Oxidation Catalytic converter. A catalytic converter system that reduces levels of HC and CO.
OCT ADJ: Octane Adjust. Compensating strategy that adjusts for changes in fuel octane.
OEM: Original Equipment Manufacturer.
OHC: OverHead Cam. An engine configuration that uses a single camshaft positioned above the
valves.
OWL: Overheat Warning Lamp or its signal output from the PCM. Turns the TEMP warning lamp
ON when engine oil temperature exceeds safe limits.
Open Circuit: A circuit which does not provide a complete path for flow of current.
OL: Open Loop. An operating condition based on instructions not modified by PCM feedback.
O(2)S 11/12/21/22: Oxygen Sensor and its relative position in the exhaust system. Detects oxygen
content in exhaust gasses.
OSC: Output State Control.
OSS: Output Shaft Speed.
Ozone: A blue gaseous form of oxygen (O(3)) formed naturally by electric discharge or exposure to
ultraviolet radiation.
Particulate: Small solid matter found in exhaust gases, especially prevalent in diesel engines.
PATS: Passive Anti-Theft System.
PATSIL: Passive Anti-Theft System Indicator Light.
PATSIN: Passive Anti-Theft System Receive Signal.
PATSOUT: Passive Anti-Theft System Transmit Signal.
PATSTRT: Passive Anti-Theft System Starter Relay Control
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PCM: Powertrain Control Module. Formerly known as the EEC (Electronic Engine Control)
Processor.
PCV: Positive Crankcase Ventilation. A system which allows the controlled flow of crankcase
vapors into the combustion chamber.
PF: Purge Flow. Amount of fuel vapor burned in the engine.
Photochemical: Term describing the action of light on air pollutants which results in creating smog.
PID: Parameter Identifier. Identifies an address in PCM memory which contains operating
information.
Powertrain: Engine and transmission/transaxle components.
Pressure - Absolute: A pressure referenced to a perfect vacuum.
Pressure - Atmospheric: The pressure of the surrounding air at any given temperature and altitude.
Sometimes called Barometric Pressure.
Pressure - Barometric: Pertaining to atmospheric pressure or the results obtained by a barometer.
Pressure - Differential: The pressure difference between two regions, such as between the intake
manifold and atmospheric pressure.
Pressure - Gage: The amount by which absolute pressure exceeds the ambient atmospheric
pressure.
PIP: Profile Ignition Pickup. Provides crankshaft position information for ignition synchronization.
Potentiometer: An adjustable resistance component commonly used as a sensor (Example: TP
Sensor).
PPM: Parts Per Million. A measure used in emission analysis.
PROM: Programmable Read-Only Memory. Similar to ROM except without program instructions.
Protocol: A set of rules for the exchange of information on a network.
PSOM: Programmable Speedometer/Odometer Module. A module that processes vehicle speed
information.
PSP: Power Steering Pressure. Indicates the pressure in the power steering system.
PSP V: Power Steering Pressure Input Voltage.
PTEC: Powertrain Electronic Controller.
PTO: Power Take-Off.
PW: Pulse Width. The length of time an actuator, such as a fuel injector, remains energized.
PWM: Pulse Width Modulation. Controls the intensity of an output by varying the signal duty cycle.
PWR GND: Power Ground. The main ground circuit in the EEC system.
Quick Test: A series of diagnostic tests of the EEC system consisting of KOEO, KOER and
Continuous Memory Self-Tests. Results are displayed as a series of DTCs.
RABS: Rear Antilock Brake System.
RAM: Random Access Memory. Memory into which information can be written as well as read.
REDOX: Reduction Oxidation Catalytic converter. A catalytic converter system designed to operate
at high temperatures.
Regulator: Controls the alternator/generator field current to maintain proper battery charge.
Contained within the PCM in smart charging applications.
Relay: An electromechanical device in which connections in one circuit are opened or closed by
changes in another circuit.
REM: Rear Electronic Module.
Repetitive Spark: Multiple firings of individual spark plugs at engine speeds below 1000 RPM to
improve idle quality and improve emissions.
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RF: Radio Frequency.
RFI: Radio Frequency Interference.
RFS: Returnless Fuel System.
RM: Relay Module. A module containing two or more relays.
ROM: Read-Only Memory. Computer memory that can be accessed and utilized, but not altered.
RON: Research Octane Number.
Routine: A group of related tasks, such as a series of diagnostic tests.
RPM: Revolutions Per Minute.
RS: Reverse Switch.
RTN: Return. A dedicated sensor ground circuit.
RWD: Rear Wheel Drive.
SAE: Society of Automotive Engineers.
SBS: Supercharger Bypass Solenoid or its signal output from the PCM.
SC: Supercharged or Supercharger.
SCB: Supercharger Bypass Control. A system that allows manifold vacuum to be bled away from
the supercharger wastegate actuator to allow for maximum boost.
SCBF: Supercharger Bypass Control Fault. Identifies whether a fault exists in the Supercharger
Bypass circuit.
SCICP: Supercharger Intercooler Pump Control.
SCICPF: Supercharger Intercooler Pump Control Fault.
SCIPC: The PID to monitor the operation of the Supercharger and Charge Air Cooler pump.
SCP: Standard Corporate Protocol.
Self- Test: See Quick Test.
Sensor: A device that detects the value or change in a physical quantity, such as temperature,
pressure or flow rate, and converts the data into an electrical signal.
SFI: Sequential Multi port Fuel Injection. A multiport fuel delivery system where each injector is
individually energized and timed relative to its cylinder intake event.
Shield: A conducting sleeve that surrounds wires to be electronically isolated from Electromagnetic
Interference (EMI).
Short Circuit: An undesirable condition in a circuit where it is terminated at a point other than that
intended.
SHRT FT: Short-Term Fuel Trim. Fuel flow adjustment in response to the HO2S sensor(s) input
during closed-loop operation.
SIG RTN: Signal Return. A dedicated sensor ground circuit that is common to two or more sensors.
SIL: Shift Indicator Lamp.
Smart Driver: A PCM or ECU output driver that can detect faults (open or shorts) on its output
circuit.
SME: Society of Manufacturing Engineers.
SOF: Shift-On-the-Fly.
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SOHC: Single Overhead Cam.
Solenoid: A device consisting of an electrical coil which produces a magnetic field in a plunger and
pulled to a central position.
ST: Scan Tool. A device that interfaces with and communicates information on a data link.
Stoichiometry: An air/fuel mixture that is neither too rich nor too lean. Stoichiometric ratio is 14.7
parts of air for every 1 part of fuel.
Switch: A device for making, breaking, or changing the connections in an electrical circuit.
TA: Traction Assist.
TACH: Tachometer.
TB: Throttle Body. A device that controls airflow through the engine via a butterfly valve, and has
an air bypass channel around the throttle plate.
TC: 1. Traction Control. Combines anti-lock braking and axle torque reduction to control wheel
slippage. 2. Turbocharger.
TDC: Top Dead Center.
Tear Tag: The two-piece adhesive label attached to the PCM to identify its calibration.
Thermistor: A temperature dependent resistor, like that used in CHT and ECT sensors.
Timing: Relationship between spark plug firing and piston position expressed in crankshaft degrees
before (BTDC) or after (ATDC) top dead center of the compression stroke.
TMAP: Thermal Manifold Absolute Pressure Sensor. A MAP Sensor that includes a thermistor to
measure intake air temperature.
TP: Throttle Position (sensor). A three-wire potentiometer that provides throttle angle and rate
information for the PCM.
TP V: Throttle Position Sensor Voltage.
Transducer: A device that receives energy from one medium and transfers it to another. For
example, thermal energy is converted to an electrical signal through a temperature probe.
Transmissions/Transaxles:
NOTE: All related items are grouped under the general heading "TRANSMISSIONS" located at the
end.
TSB: Technical Service Bulletin. Notifies service personnel of any known vehicle concerns,
procedures, or general service information.
Underspeed Mode: A control mode that prevents the engine from stalling in the event it stumbles
while running. Also used during engine crank.
Vacuum: Manifold pressure that is reduced below the ambient atmospheric pressure.
Variable Reluctance: A process of passing a varying magnetic field through wire windings and
inducing a voltage.
VCT: Variable Camshaft Timing.
VECI: Vehicle Emission Control Information label.
VIN: Vehicle Identification Number. A unique identification number given to every vehicle produced.
Includes information about the year, model, engine, and plant origin of the vehicle.
VMV: Vapor Management Valve. Controls the flow of fuel vapors out of the carbon canister.
VOM: Volt-Ohm Meter. Readings are indicated by sweep hand on a printed scale rather than a
digital (DVOM) display.
VPWR: Vehicle Power. A switched circuit that provides power to the EEC system. Compare
"Battery Voltage
VREF: Reference Voltage. A dedicated circuit that provides approximately a 5.0 volt signal used as
a reference by certain sensors.
WAC: Wide Open Throttle A/C Cut-off. Turns A/C system off during wide open throttle or certain
other operating conditions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Description and Operation > Acronyms and Definitions > Page 4942
Wastegate Control: A device that opens the wastegate in case of overboost from a turbocharger.
WOT: Wide Open Throttle. A condition of maximum airflow through the throttle body.
Zip Tube: Another name for "fresh air duct" or "air inlet duct".
TRANSMISSIONS:
NOTE: The transmission naming convention is as follows:
^ The first character, a number, is the number of forward gears.
^ The second character, either the letter "F" or "R," represents front (transaxle) or rear
(transmission) wheel drive.
^ The next set of characters, a grouping of numbers, represents the design torque capacity of the
transmission/transaxle (for example, "27" represents 270ft./lbs. in the 4F27E transaxle).
^ The last character, if used, is one of the following:
^ "E" for electronic shift
^ "N" for non-synchronous shift
^
"S" for synchronous shift
^ "W" for wide ratio
^ 4F27E: Also known as the FN Focus automatic transmission.
^ 4F44E: Formerly known as the CD4E.
^ 4F46S: Formerly known as the Ax45 and regular-duty AXOD-E.
^ 4F50N: Formerly known as the Ax4N and heavy-duty AXOD-E.
^ 4R44E: Formerly known as A4LD for 3.0L applications.
^ 4R55E: Formerly known as A4LD for 4.0L applications.
^ 4R70W: Formerly known as AOD-E.
^ 4R100: Formerly known as E4OD.
^ 5R44E: Formerly known as A5LD for 3.0L applications.
^ 5R55E: Formerly known as A5LD for 4.0L applications.
^ 5R55N: Lincoln LS automatic transmission.
^ 5R55W: Wide-ratio truck transmission.
^ 4x4L: 4x4 Low.
^ A/T: Automatic Transmission.
^ CCS: Coast Clutch Solenoid.
^ CCSF: Coast Clutch Solenoid Fault. Displays a YES if fault exists.
^ EPC: Electronic Pressure Control.
^ EPCV: Electronic Pressure Control Volts.
^ ESS: Electronic Shift Scheduling.
^ HCDSS: High Clutch Drum Speed Sensor. PCM input from the 4R44E and 4R55E.
^ M5OD: Manual 5-Speed transmission with overdrive (RWD).
^ M/T: Manual Transmission/Transaxle.
^ NPS: Neutral Pressure Switch or its signal input to the PCM.
^ OCS: Overdrive Cancel Switch.
^ OSS: Output Shaft Speed. Indicates rotational speed of the transmission output shaft.
^ PNP: Park/Neutral Position switch. Also known as Neutral Drive Switch (NDS), Neutral Gear
Switch (NGS), and Transmission Switch Neutral (TSN).
^ REVERSE or REV: Transmission Reverse Switch Input.
^ SIL: Shift Indicator Lamp. A lamp that indicates the preferred shift points on select manual
transmission/transaxle vehicles.
^ S91/SS2/SS3: Shift solenoids. Devices that control the shifting in an automatic transmission.
^ TCC: Torque Converter Clutch. When energized, causes a mechanical engagement and
disengagement of the Torque Converter Clutch.
^ TCIL: Transmission Control Indicator Lamp. Indicates that the Transmission Control Switch (TCS)
has been activated.
^ TCS: Transmission Control Switch. Modifies the operation of electronically controlled
transmissions.
^ Torque converter: A device which by its design multiplies the torque in a fluid coupling between
an engine and transmission/transaxle.
^ TFT: Transmission Fluid Temperature. Indicates temperature of transmission fluid.
^ Transaxle: A device consisting of a transmission and axle drive gears assembled in the same
case. Front-wheel drive applications.
^ Transmission: A device which selectively increases or decreases the ratio of relative rotation
between its input and output shafts. Rear-wheel drive applications.
^ TR: Transmission Range. The range in which the transmission is operating.
^ TR Sensor: Formerly known as Manual Lever Position Sensor (MLPS). Provides information to
the PCM on the transmission range selector position.
^ TR V: Transmission Range Voltage.
^ TSS: Turbine Shaft Speed. Indicates rotational speed of the transmission turbine shaft.
^ VSS: Vehicle Speed Sensor. A magnetic pickup device that generates an AC signal that is
proportional to vehicle speed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Description and Operation > Acronyms and Definitions > Page 4943
Positive Crankcase Ventilation: Description and Operation Positive Crankcase Ventilation System
Positive Crankcase Ventilation System
Overview
The Positive Crankcase Ventilation (PCV) System (Figure 132) cycles crankcase gases back
through the engine where they are burned. The PCV valve regulates the amount of ventilating air
and blow-by gas to the intake manifold and prevents backfire from traveling into the crankcase. The
PCV valve should be mounted in a vertical position. On some applications, the PCV system is
connected to the evaporative emission system (refer to the VECI decal).
CAUTION: Do not remove the PCV system from the engine. Removal of the PCV system will
adversely affect the fuel economy and engine ventilation and result in shorter engine life.
PCV System
HARDWARE
PCV Internal Drawing
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Description and Operation > Acronyms and Definitions > Page 4944
Typical PCV Vacuum Connector
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Component Information > Description and Operation > Page 4945
Positive Crankcase Ventilation: Testing and Inspection
For information regarding diagnosis of this system refer to Computers and Control Systems
Diagnosis.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Relays and Modules - Emission Control
Systems > Air Injection Pump Relay > Component Information > Description and Operation
Air Injection Pump Relay: Description and Operation
SOLID STATE RELAY
Solid State Relay
The solid state relay (Figure 124) switches the high current required for operation of the electric
AIR pump. Input control to the solid state relay comes from the Powertrain Control Module (PCM).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4959
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4960
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4961
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4962
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Recalls: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR Pressure Sensor Defect > Page 4963
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect
Technical Service Bulletin # 02M01S6 Date: 040831
Attachment I - Administrative Information
Customer Satisfaction Program 02M01-S6
Certain Vehicles Equipped with a Tube-Mounted EGR Pressure Sensor Additional EGR Pressure
Sensor Warranty Coverage
OASIS
You must use OASIS to determine if a vehicle is eligible for this program.
Note:
Submission of an "M" program claim will not remove the vehicle from OASIS because the affected
vehicles are eligible for multiple repairs if the affected condition reoccurs during the extended
warranty time/mileage period.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds must be claimed on a repair line that is separate from the repair line that the FSA is
claimed on.
CLAIMING INSTRUCTIONS FOR REPAIRS WITH A REPAIR DATE ON OR AFTER 10/27/03
Claims for all vehicles that are within the New Vehicle Warranty Coverage must be submitted as a
warranty repair. ACESII will not accept claims for reimbursement under the 02M01 program for
vehicles within New Vehicle Warranty Coverage. Vehicles that have branded titles are eligible for
this repair under the 02M01 program.
Vehicles within New Vehicle Warranty Coverage
Claims are to be submitted as a normal warranty claim in accordance with TSB 04-11-01.
Vehicles beyond New Vehicle Warranty Coverage (including branded titled vehicles)
Claims are to be submitted following program 02M01 guidelines.
Future Warranty Extension Customer Satisfaction Programs (CSP)
Future Warranty Extension CSPs will follow these claiming instructions; only those vehicles outside
the New Vehicle Warranty Coverage will be submitted as a CSP type repair.
OWNER REFUNDS
Ford Motor Company will only refund owner-paid repairs made on or before the last day of the
month of the date of the Owner Letter (or after the date of the Owner Letter if an emergency repair
was made away from the servicing dealer). Failure of the EGR Pressure Sensor (9J460) will not
have an impact on any other component of the vehicle. Therefore, refunds will only be granted for
the replacement of the EGR Pressure Sensor (9J460).
All supporting documentation must be retained in accordance with the Warranty and Policy Manual.
Refer to ACESII manual for refund information.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor Allowances and Parts Ordering Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4969
LABOR ALLOWANCES
[NEW] NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Special Notes:
^ 02M01C labor operation is in effect for repairs performed on or after 10/27/03.
^ Diagnostics performed beyond retrieving continuous DTC will not be paid for under this program.
^ Pinpoint diagnostics are not required to identify a failed EGR Pressure Sensor; therefore labor
time has been adjusted accordingly.
^ Due to the use of specific DTCs to identify a failed EGR Pressure Sensor, this program will not
cover any other continuous DTCs; normal vehicle warranty would apply for any other DTCs.
^ There will be no related damage claims allowed for this program.
PARTS REQUIREMENTS
Parts will not be direct shipped for this program. Order your parts requirement through normal order
processing.
PARTS REQUIREMENTS/ORDERING INFORMATION
NOTE:
If service is requested on a dash mounted EGR pressure sensor (during the extended warranty
coverage period) on a 2002 Focus equipped with a 2.0L Zetec engine, call the Special Service
Support Center.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4970
DEALER PRICE
For latest prices, check DOES II or updated price book.
PARTS RETENTION
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
SERVICE PROCEDURE
NOTE:
If a 2002 Focus equipped with a 2.0L Zetec engine and a dash-mounted EGR pressure sensor is
encountered, call the Special Service Support Center.
1. Retrieve continuous DTCs.
NOTE:
Replace the EGR pressure sensor only if one or more of the following continuous DTCs are
present:
^ P1400 - DPF EGR SENSOR CIRCUIT LOW VOLTAGE DETECTED
^ P1401 - DPF EGR SENSOR CIRCUIT HIGH VOLTAGE DETECTED
^ P0401- EGR FLOW INSUFFICIENT DETECTED
^ P0402- EGR FLOW EXCESSIVE DETECTED
Any other DTC present is not covered by this program.
2. If one or more of the DTCs listed above is present, replace the EGR pressure sensor (9J460) as
follows:
a) Key off.
b) Disconnect the electrical connector and remove the EGR pressure sensor from the EGR tube.
c) Install the new EGR pressure sensor onto the EGR tube and connect the electrical connector.
Note: Refer to Section 303-08 of the appropriate workshop manual if additional information is
required.
3. Clear continuous DTCs.
4. Perform KOEO and KOER self tests.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4971
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4972
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 02M01S6 > Aug > 04 > Recall - Tube Mounted EGR
Pressure Sensor Defect > Page 4973
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4978
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4979
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4980
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set
Pressure Feedback Exhaust Sensor: All Technical Service Bulletins Emissions - MIL
ON/Driveability Issues/DTC's Set
Article No. 04-11-1
06/08/2004
DRIVEABILITY - STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON
AND DTCS P0401, P0402, P1400 OR P1401 - ADDITIONAL SYMPTOMS MAY INCLUDE RUNS
ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY
FORD: 2000-2002 TAURUS 2001-2002 CROWN VICTORIA, FOCUS, MUSTANG 2001
EXPLORER USPS 2001-2002 E SERIES, ESCAPE, EXPEDITION, EXPLORER SPORT TRAC,
EXPLORER SPORT, F-150, RANGER, WINDSTAR 2002-2003 EXPLORER
LINCOLN: 2001-2002 TOWN CAR
MERCURY: 2000-2002 SABLE 2001-2002 COUGAR, GRAND MARQUIS 2002-2003
MOUNTAINEER
This article supersedes TSB 04-3-1 to update service part information and applications.
ISSUE
Some vehicles may exhibit a malfunction indicator lamp (MIL) "ON" with or without the following
symptoms: Rough Running, Lack of Power, Surge or Poor Fuel Economy, along with diagnostic
trouble codes (DTC's) P0401, P0402, P1400 or P1401. This may be caused by an intermittently
functioning tube-mounted delta pressure feedback EGR (DPFE) sensor (Figure 1).
ACTION
For vehicles equipped with a tube-mounted DPFE sensor, perform the following diagnostic
procedure and repair action. This procedure supersedes the diagnostic procedure in the PC/ED
Manual for the issue described above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4986
NOTE
ALL LISTED APPLICATIONS CAN NOW BE SERVICED WITH DPFE SENSOR 4U7Z-9J460-AA
NOTE
THIS ARTICLE APPLIES TO THE FULL MODEL YEAR FOR ALL VEHICLES SHOWN EXCEPT
THE FOLLOWING:
^ 2002 Taurus/Sable 3.0L DOHC - Built After May 2002
^ 2002 Taurus/Sable 3.0L OHV - Built After February 2002
^ 2002 Econoline And F-150 4.2L OHV - Built After April 9, 2002
^ 2003 Explorer 4dr/Mountaineer 4.6L SOHC - Built After February 2, 2003
SERVICE PROCEDURE
1. Retrieve continuous DTC(s).
2. If P0401, P0402, P1400 or P1401 are present, turn ignition OFF and replace the DPFE sensor.
3. Clear continuous DTC(s).
4. Perform key on engine off (KOEO) and key on engine running (KOER) self-test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4987
Labor Operations
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of New Vehicle Limited Warranty Coverage
And Emissions Warranty Coverage.
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J460 42
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Pressure Feedback Exhaust Sensor: > 04-11-1 > Jun > 04 > Emissions - MIL ON/Driveability
Issues/DTC's Set > Page 4988
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4989
Pressure Feedback Exhaust Sensor: Specifications
Differential Pressure Feedback EGR Bolts 8 - 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4990
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4991
Pressure Feedback Exhaust Sensor: Description and Operation
DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
Differential Pressure Feedback EGR Sensor
The differential pressure feedback EGR sensor (Figure 86) is a ceramic, capacitive-type pressure
transducer that monitors the differential pressure across a metering orifice located in the orifice
tube assembly. The differential pressure feedback sensor receives this signal through two hoses
referred to as the downstream pressure hose (REF SIGNAL) and upstream pressure hose (HI
SIGNAL). The HI and REF hose connections are marked on the aluminum differential pressure
feedback EGR sensor housing for identification (note that the HI signal uses a larger diameter
hose). The differential pressure feedback EGR sensor outputs a voltage proportional to the
pressure drop across the metering orifice and supplies it to the PCM as EGR flow rate feedback.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4992
Tube Mounted Differential Pressure Feedback EGR Sensor
TUBE MOUNTED DIFFERENTIAL PRESSURE FEEDBACK EGR SENSOR
The tube mounted differential pressure feedback EGR sensor (Figure 87) is identical in operation
as the larger metal or plastic DPFE sensors and uses a 1.0 volt offset. The HI and REF hose
connections are marked on the underside of the sensor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4993
Pressure Feedback Exhaust Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the differential pressure feedback EGR electrical connector.
3. Disconnect the differential pressure feedback EGR hoses.
4. Remove the bolts and the differential pressure feedback EGR.
INSTALLATION
1. Fit the differential pressure feedback EGR and loosely install the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission
Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Technical Service Bulletins >
Page 4994
2. Tighten the bolts.
3. Connect the differential pressure feedback EGR hoses.
4. Connect the differential pressure feedback EGR electrical connector. 5. Connect the battery
ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Specifications
Fuel Pressure Test Port: Specifications
Fuel Pressure Relief Valve Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Technician Safety Information > Page 5002
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 5003
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure Test
Port > Component Information > Service Precautions > Page 5004
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel
supply line.
3. Remove the four bolts and the fuel supply line from the fuel supply manifold.
4. Remove the fuel supply line bracket bolt and the fuel supply line.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G, to aid installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions > Page 5008
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL SERVICE TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure.
NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service Precautions > Page 5009
Fuel Pressure Gauge
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications > With 104 Pin Processor
Idle Speed: Specifications With 104 Pin Processor
Hot Idle ................................................................................................................................................
......................................................... 670 - 750 RPM
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information >
Specifications > With 104 Pin Processor > Page 5014
Idle Speed: Specifications With 150 Pin Processor
With Automatic Transmission
Hot Idle ................................................................................................................................................
.................................................................. 750 RPM
With Manual Transmission
Hot Idle ................................................................................................................................................
.................................................................. 750 RPM
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Accelerator Pedal: Specifications
Accelerator Pedal And Shaft Pivot Screw 9 - 12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 5018
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 5019
Accelerator Pedal: Description and Operation
The accelerator cable is controlled by an accelerator pedal and shaft. The pedal and shaft should
travel smoothly from the idle to wide-open throttle positions. Failure to return or hesitation on return
to the idle position must not occur.
Surrounding components such as wiring, hoses, sound insulator and floor covering must not
contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft.
The speed control speedometer cable and the accelerator cable are attached at the throttle lever
on the throttle body.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Accelerator Pedal: Initial Inspection and Diagnostic Overview
NOTE: Care should be exercised when performing service on or around the accelerator pedal
linkage and controls.
1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which
would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may
cause bending. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed
specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for
excessive wear or damage.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5022
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Cable
Accelerator Pedal: Service and Repair Cable
REMOVAL
1. Remove the screws and the accelerator control splash shield.
2. Disconnect the accelerator cable from the throttle body.
3. Disconnect the accelerator cable from the intake manifold.
1 Remove the screw.
2 Disconnect the accelerator cable from the intake manifold.
4. From inside the vehicle, disconnect the accelerator cable from the accelerator pedal and shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Cable > Page 5025
5. Collapse the clips at the dash panel and push the accelerator cable through the dash panel into
the engine compartment and remove the accelerator
cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Service and Repair > Cable > Page 5026
Accelerator Pedal: Service and Repair Pedal
REMOVAL
1. Disconnect the accelerator cable from the accelerator pedal and shaft. See: Cable
2. Remove the accelerator pedal and shaft pivot screw, and remove the accelerator pedal and
shaft.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Component
Information > Service and Repair
Air Cleaner Housing: Service and Repair
REMOVAL
1. Disconnect the air cleaner assembly.
^ Loosen the clamp and disconnect the outlet tube.
^ Disconnect the Mass Air Flow (MAF) sensor electrical connector.
2. Remove the air cleaner assembly.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Specifications
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Nuts And Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Specifications > Page 5033
Mass Air Flow Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Specifications > Page 5034
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Specifications > Page 5035
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow
Meter/Sensor] > Component Information > Specifications > Page 5036
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Loosen the air cleaner outlet tube clamp and position aside.
4. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle
Technical Service Bulletin # 03-3-5 Date: 030217
Engine Controls - No Start/Hard Start/Rough Idle
Article No. 03-3-5
02/17/03
DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS
FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 2000-2002 LS
MERCURY: 2000-2003 SABLE, MOUNTAINEER
ISSUE
Some vehicles, may exhibit drivability conditions.
These may include:
^ No start Difficult to start Stall
^ Low idle
^ Rough idle
^ High idle
^ Hesitation/surge while accelerating or at steady speed
These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction
Indicator Lamp (MIL). In some cases DTC and MIL may be evident.
ACTION
Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following
procedure is supplemental information to normal diagnostics to facilitate accurate identification of
malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling
problems, and Idle Speed Control System related DTC's.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5045
If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will
assist the technician making a correct repair the first time.
Perform normal diagnostics.
SERVICE INFORMATION
NOTE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5046
IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE
CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF
THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400,
698298
Disclaimer
IAC Diagnostic Service Tips - General
Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair
the drivability concern, but the long-term functionality of the valve is compromised.
For all drivability concerns, make certain the service writer obtains as much information as possible
from the customer as to the conditions causing drivability concern. Attached is a drivability concern
check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle.
NOTE
IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE
POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON
DECELERATION.
Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and
Lincoln LS.
1. Use the following conditions for the test described below:
^ Transmission in park
^ Engine temperature should be at least 190° F (88°C)
^ All accessories should be off steering wheel in the center position
^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system
^ Short and long term fuel trims less than 15%
^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission
Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the
chart in this TSB.
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure that there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird.
1. Use the following conditions for the test described below:
^ Transmission in park
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5047
^ Engine idle at approximately 650 RPM
^ Engine temperature should be at least 190° F (88° C)
^ All accessories and the engine cooling fan should be off
^ Steering wheel in the center position
^ EGRVR and EVAPDUTY CYCLE are zero
^ Short and long term fuel trims less than 15%
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
NOTE
IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650
RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER
THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND
CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM.
At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with
no purge flow (EVAPV duty cycle is 0%).
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
NOTE
IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY
CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER
DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN.
Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer,
Mountaineer, Explorer Sport and Explorer Sport Trac.
If no DTC's present check the following items in this order before examining the IAC valve:
^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB
^ Battery and fuse box power lead
^ Ground wire attachments
^ Wiring (wiggle test)
^ PCM voltage
^ Vacuum leaks
Examine AC valve under these conditions:
^ PCM updated to the latest available calibration
^ Transmission in park
^ Warm stabilized vehicle with engine temperature at least 190° F (88° C)
^ All accessories and cooling fan sh6uld be off
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5048
^ Steering wheel in the center position
^ EGVR and EVAPDC at zero, if the vehicle has an EGR system
^ Short and long term fuel trims (less than 15)
Perform the following steps in order:
1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3.
2. Allow vehicle to idle until the IACTRIM PID is 0.
NOTE
IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID
SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING
SHOULD BE TURNED OFF.
3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at
idle. The remainder of this TSB will help diagnose true root cause.
4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to
include the throttle body and air intake system) -is not operating properly.
NOTE
FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM
IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC.
IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns:
^ There are two primary causes of high idle:
1. Damaged IAC valves and
2. Vacuum leaks
^ AC valves can be damaged from engine induction backfires. Many times the customer may not
notice the induction backfire but will notice the high idle afterwards. Indications of valve damage
can be a shiny, almost polished appearance in the interior of the valve and a dislocated
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5049
pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1.
^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also
verify that the correct PCV valve is installed.
^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction
backfire can loosen or disconnect vacuum hoses.
^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear
normal in the service bay. If the duty cycle is below specification that is indicative that the engine is
receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to
restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS
(LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this
is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to
compensate.
IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle
Concerns:
^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on
the engine or obstruction in the air intake system could also reduce the engine RPMs.
^ There are four possible sources of friction load that can contribute to under speed error or low
idle concerns.
1. Power Steering Load
2. Air Conditioning Load
3. Electrical Load
4. Automatic Transmission Torque Converter Load
EAC Diagnostic Service Tips - Rough Idle
Concerns:
^ Rough idle concerns are often a result of a lean running condition
^ Another possible cause is contamination build up on the MAF sensor
EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start
^ While performing diagnostics, the technician should ensure that the fuel system is working
correctly for all engines with hard start/crank no-start complaints.
^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED
pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure
test:
^ Perform the KOEO fuel pressure test as specific in the PC/ED manual.
^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55
psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the
start of the test.
^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test.
^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible
after pump shut off, no more than 5 minutes after the start of the test.
NOTE
RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED
USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC.
IAC Diagnostic Service Tips - High Idle RPM at Start Up:
^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If
DTC 1506 is not present, this indicates that there is no fault present with the IAC.
^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast
idle (1600-2500 RPM that decreases slowly). No
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5050
repairs should be attempted because this is a normal temporary PCM calibration strategy to
prevent spark plug fouling during plant/transportation operation. The calibration will permanently
revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A
brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle
has been below 4 miles at a time.
IAC Diagnostic Service Tips - EAC Valve Noise Issues
For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire.
NOTE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > Customer Interest for Auxiliary Air Valve (Idle Speed): > 03-3-5 >
Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5051
ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS
FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE
IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE
IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE,
COMPARE AGAINST A LIKE VEHICLE.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle
Technical Service Bulletin # 03-3-5 Date: 030217
Engine Controls - No Start/Hard Start/Rough Idle
Article No. 03-3-5
02/17/03
DRIVEABILITY - IDLE AIR CONTROL (IAC) VALVE DIAGNOSTIC SERVICE TIPS
FORD: 2000-2003 TAURUS 2002 THUNDERBIRD 2000-2003 EXPLORER, RANGER 2001-2003
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 2000-2002 LS
MERCURY: 2000-2003 SABLE, MOUNTAINEER
ISSUE
Some vehicles, may exhibit drivability conditions.
These may include:
^ No start Difficult to start Stall
^ Low idle
^ Rough idle
^ High idle
^ Hesitation/surge while accelerating or at steady speed
These conditions may be intermittent with no Diagnostic Trouble Codes (DTC) and no Malfunction
Indicator Lamp (MIL). In some cases DTC and MIL may be evident.
ACTION
Trouble cannot be identified with 95% of returned Idle Air Control (IAC) valves. The following
procedure is supplemental information to normal diagnostics to facilitate accurate identification of
malfunctioning valves. These symptoms would include engine stall, hard start, crank/no start, idling
problems, and Idle Speed Control System related DTC's.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5057
If the service writer uses the worksheet (Figure 2) for all drivability concerns including stalls it will
assist the technician making a correct repair the first time.
Perform normal diagnostics.
SERVICE INFORMATION
NOTE
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5058
IT MAY NOT BE POSSIBLE TO DUPLICATE THE CUSTOMER CONCERN. ALTHOUGH THE
CONDITION MAY NOT BE DUPLICATED, IT IS RECOMMENDED THAT ANY EVALUATION OF
THE IAC VALVE BE DONE IN ACCORDANCE WITH THE FOLLOWING SERVICE PROCEDURE.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 602300 603300, 607000, 607400, 607700, 608000, 608400, 611000, 618400, 619400,
698298
Disclaimer
IAC Diagnostic Service Tips - General
Never clean an IAC valve. Carburetor cleaners and other cleaning agents may temporarily repair
the drivability concern, but the long-term functionality of the valve is compromised.
For all drivability concerns, make certain the service writer obtains as much information as possible
from the customer as to the conditions causing drivability concern. Attached is a drivability concern
check off sheet (Figure 2) that if used, can help reduce the time required to diagnose a vehicle.
NOTE
IF THE ENGINE STALLED WHILE THE VEHICLE WAS IN GEAR AND MOVING THE
POSSIBILITY OF THE IAC VALVE CAUSING THIS IS UNLIKELY UNLESS IT OCCURRED ON
DECELERATION.
Use the following Supplemental information for 3.0L 4V Duratec Engines, in the Taurus/Sable, and
Lincoln LS.
1. Use the following conditions for the test described below:
^ Transmission in park
^ Engine temperature should be at least 190° F (88°C)
^ All accessories should be off steering wheel in the center position
^ EGVR and EVAPDUTY CYCLE at zero, if the vehicle has an EGR system
^ Short and long term fuel trims less than 15%
^ At stabilized engine speed (RPM) and temperature (hot idle) per the Powertrain Control Emission
Diagnostics (PC/ED) manual, verify the IAC duty cycle is within reference values called out in the
chart in this TSB.
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure that there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
Use the following Supplemental Information for the 3.9L Lincoln LS and Thunderbird.
1. Use the following conditions for the test described below:
^ Transmission in park
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5059
^ Engine idle at approximately 650 RPM
^ Engine temperature should be at least 190° F (88° C)
^ All accessories and the engine cooling fan should be off
^ Steering wheel in the center position
^ EGRVR and EVAPDUTY CYCLE are zero
^ Short and long term fuel trims less than 15%
NOTE
IT IS USUAL TO SEE THE IAC DUTY CYCLE VARY BY 1% TO 2% OVER SEVERAL MINUTES.
NOTE
IT IS EXTREMELY IMPORTANT TO CHECK THE IAC DUTY CYCLE WHEN THE RPM IS AT 650
RPM. EVEN 700 RPM IS TOO HIGH FOR CHECKING the IAC VALVE DUTY CYCLE UNDER
THESE CONDITIONS. IF THE RPM IS OVER 650 RPM, MOMENTARILY OPENING AND
CLOSING THE THROTTLE AND A SHORT EQUILIBRATION TIME WILL LOWER THE RPM.
At stabilized engine speed and temperature, verify that the IAC duty cycle is between 27-36% with
no purge flow (EVAPV duty cycle is 0%).
If the Duty Cycle is out of specification, proceed with the following steps:
1. Ensure there is no purge flow.
2. Verify PCM harness integrity by performing a wiggle test on the harness while the engine is
running and observe the IAC duty cycle and engine performance. Should abnormalities be
observed, repair the harness as required.
3. For an IAC duty cycle high concern, unplug and plug in the IAC power connector several times.
If the duty cycle remains high, replace IAC valve.
4. For an IAC duty cycle low concern, there may be an intake air leak. See the below IAC
diagnostic service tip for DTC 1506 and other high idle concerns.
NOTE
IF THE ORIGINAL IAC VALVE WAS WITHIN DUTY CYCLE SPECIFICATION OR THE DUTY
CYCLE REMAINS OUT OF SPECIFICATIONS AFTER IAC VALVE REPLACEMENT FURTHER
DIAGNOSTICS ARE REQUIRED TO ADDRESS THE CUSTOMER CONCERN.
Use the following Supplemental Information for 4.0L SOHC Engines In the Ranger, Explorer,
Mountaineer, Explorer Sport and Explorer Sport Trac.
If no DTC's present check the following items in this order before examining the IAC valve:
^ BARO Hz reading - Refer to Barometric Pressure Chart listed in this TSB
^ Battery and fuse box power lead
^ Ground wire attachments
^ Wiring (wiggle test)
^ PCM voltage
^ Vacuum leaks
Examine AC valve under these conditions:
^ PCM updated to the latest available calibration
^ Transmission in park
^ Warm stabilized vehicle with engine temperature at least 190° F (88° C)
^ All accessories and cooling fan sh6uld be off
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5060
^ Steering wheel in the center position
^ EGVR and EVAPDC at zero, if the vehicle has an EGR system
^ Short and long term fuel trims (less than 15)
Perform the following steps in order:
1. Using either NGS or WDS bring up the following PIDS: IACTRIM, IACKAM2, IACKAM3.
2. Allow vehicle to idle until the IACTRIM PID is 0.
NOTE
IACTRIM ALWAYS TRIES TO GO TO 0. WHEN MOVING TOWARDS 0, THE IACKAM2 PID
SHOULD BE CHANGING. IF IACKAM3 IS CHANGING, THEN THE AIR CONDITIONING
SHOULD BE TURNED OFF.
3. If IACKAM2 is between -0.35 and +0.35 with IACTRIM=0, then the valve is operating properly at
idle. The remainder of this TSB will help diagnose true root cause.
4. If IACKAM2 is not between -0.35 and +0.35, it is highly likely that the engine idle system (to
include the throttle body and air intake system) -is not operating properly.
NOTE
FOR ALL VEHICLES PLEASE RECORD THE OBSERVED IAC DUTY CYCLE AND ENGINE RPM
IN THE WARRANTY CLAIMS COMMENTS FOR THIS DIAGNOSTIC.
IAC Diagnostic Service Tips - DTC 1506 (IAC Over Speed Error) and other High Idle Concerns:
^ There are two primary causes of high idle:
1. Damaged IAC valves and
2. Vacuum leaks
^ AC valves can be damaged from engine induction backfires. Many times the customer may not
notice the induction backfire but will notice the high idle afterwards. Indications of valve damage
can be a shiny, almost polished appearance in the interior of the valve and a dislocated
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5061
pintle. An IAC valve damaged by backfire should be replaced. Refer to Figure 1.
^ Inspect PCV system for leaks especially looking for cracks along any rubber elbow joints; also
verify that the correct PCV valve is installed.
^ Inspect for vacuum hoses loose or disconnected from intended ports and connections. Induction
backfire can loosen or disconnect vacuum hoses.
^ Two indicators can help you identify if a vacuum leak is present, even if the engine RPM appear
normal in the service bay. If the duty cycle is below specification that is indicative that the engine is
receiving too much air (from a vacuum leak) and the PCM is ordering the valve to close up to
restrict flow. Another indication is fuel trim. Record the long term and short term fuel trim PIDS
(LONGFT1, LONGFT2, SHORTFT1, etc.), if short term fuel trims are high (above specification) this
is a possible indication of a vacuum leak, making the engine run lean, and the PCM is attempting to
compensate.
IAC Diagnostic Service Tips - DTC 1507 (IAC Under Speed Error) and Other Low Idle
Concerns:
^ An under speed error may not necessarily be a fault with the IAC valve. A large friction load on
the engine or obstruction in the air intake system could also reduce the engine RPMs.
^ There are four possible sources of friction load that can contribute to under speed error or low
idle concerns.
1. Power Steering Load
2. Air Conditioning Load
3. Electrical Load
4. Automatic Transmission Torque Converter Load
EAC Diagnostic Service Tips - Rough Idle
Concerns:
^ Rough idle concerns are often a result of a lean running condition
^ Another possible cause is contamination build up on the MAF sensor
EAC Diagnostic Service Tips - Engine Hard Start/Engine Crank-No Start
^ While performing diagnostics, the technician should ensure that the fuel system is working
correctly for all engines with hard start/crank no-start complaints.
^ When diagnosing a mechanical return less fuel system, the following correction to the PC/ED
pinpoint HC (4) diagnostic procedure should be used when performing the KEOE fuel pressure
test:
^ Perform the KOEO fuel pressure test as specific in the PC/ED manual.
^ The fuel pressure should drop off no more than 10 psi from maximum pressure (no lower than 55
psi for a 65 psi max system or no lower than 45 psi for a 55 psi max system) within 5 minutes of the
start of the test.
^ The fuel pressure should drop off to no less than 30 psi within 30 minutes of the start of the test.
^ For greatest accuracy, the service technician should read the fuel pressure as soon as possible
after pump shut off, no more than 5 minutes after the start of the test.
NOTE
RETURNABLE AND ELECTRONIC RETURN LESS SYSTEMS SHOULD ALSO BE DIAGNOSED
USING THE PROCEDURES LISTED FOR THEM IN PINPOINT TEST HC.
IAC Diagnostic Service Tips - High Idle RPM at Start Up:
^ Most engines will have a temporary high idle at engine start up to allow for catalyst light off. If
DTC 1506 is not present, this indicates that there is no fault present with the IAC.
^ A vehicle with very low odometer miles, may exhibit a higher than normal temporary startup fast
idle (1600-2500 RPM that decreases slowly). No
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5062
repairs should be attempted because this is a normal temporary PCM calibration strategy to
prevent spark plug fouling during plant/transportation operation. The calibration will permanently
revert to its normal strategy after the PCM has seen its first 4 miles of continuous drive cycle. A
brand new vehicle may accumulate some mileage without turning this strategy off if the drive cycle
has been below 4 miles at a time.
IAC Diagnostic Service Tips - EAC Valve Noise Issues
For IAC valve noise concerns check for obstructed or potentially damaged IAC valve from backfire.
NOTE
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Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Auxiliary Air Valve (Idle Speed): >
03-3-5 > Feb > 03 > Engine Controls - No Start/Hard Start/Rough Idle > Page 5063
ON SOME NEWER MODEL YEAR VEHICLES THE REACTION SPEED OF THE EAC VALVE IS
FAST ENOUGH THAT IT MIGHT MAKE A "POPPING" SOUND AS IT REACTS TO A LARGE
IDLE LOAD. THIS IS A NORMAL CHARACTERISTIC AND NO ATTEMPTS SHOULD BE MADE
IN AN EFFORT TO MODIFY THE PERFORMANCE OF THE IAC VALVE. IF POSSIBLE,
COMPARE AGAINST A LIKE VEHICLE.
NOTE
REMEMBER THAT MOST WEATHER SERVICES REPORT A LOCAL BAROMETRIC
PRESSURE THAT HAS BEEN CORRECTED TO SEA LEVEL. THE BARO PID, ON THE OTHER
HAND, REPORTS THE ACTUAL BAROMETRIC PRESSURE FOR THE ALTITUDE THE
VEHICLE IS BEING OPERATED IN. LOCAL WEATHER CONDITIONS (HIGH AND LOW
PRESSURE AREAS) WILL CHANGE THE LOCAL BAROMETRIC PRESSURE BY SEVERAL
INCHES OF MERCURY (+/- 3 Hz, +/-1 in.Hg.).
NOTE
BARO IS UPDATED ONLY WHEN THE VEHICLE IS AT HIGH THROTTLE OPENINGS.
THEREFORE, A VEHICLE, WHICH IS DRIVEN DOWN FROM A HIGHER ALTITUDE MAY NOT
HAVE HAD AN OPPORTUNITY TO UPDATE THE BARO VALUE IN KAM. IF YOU ARE NOT
CONFIDENT THAT BARO HAS BEEN UPDATED, PERFORM THREE OR FOUR HEAVY,
SUSTAINED ACCELERATIONS AT GREATER THAN HALF-THROTTLE TO ALLOW BARO TO
UPDATE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Cap: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5072
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5073
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5074
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5075
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Customer Interest for Fuel Filler Cap: > 03-20-3 > Oct > 03 > Emissions - MIL
ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5076
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Cap: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap
Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5082
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5083
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5084
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5085
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Cap: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5086
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Page 5087
Fuel Filler Cap: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Page 5088
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Technical Service Bulletins > Page 5089
Fuel Filler Cap: Description and Operation
FUEL FILLER CAP
Fuel Filler Cap
The fuel filler cap (Figure 100) is used to prevent fuel spill and close the evaporative emission/fuel
system to atmosphere. Some vehicles may have a Fuel Cap Off Indicator Lamp (FCIL) in the
instrument cluster which will illuminate when there is a failure in the vapor management system
that may be due to the fuel filler cap not being sealed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions
Fuel Pressure Release: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 5094
Fuel Pressure Release: Service and Repair
Fuel Pressure Gauge
SPECIAL SERVICE TOOL(S)
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Remove the Schrader valve cap and attach the Fuel Pressure Gauge.
2. Open the manual valve on the Fuel Pressure Gauge slowly and relieve the fuel pressure.
NOTE: Open the manual valve slowly to relieve the system pressure. This may drain fuel from the
system. Place the fuel in a suitable container.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release
> System Information > Service Precautions > Page 5095
Fuel Pressure Gauge
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Service and Repair
Fuel Injector Wiring Harness: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Remove the
upper and lower intake manifolds. For additional information, refer to Engine.
3. Disconnect the three (LH) fuel injector electrical connectors.
NOTE: One connector is shown, the other two are similar.
4. Disconnect the (RH) fuel injector electrical connector.
5. Disconnect the engine bulkhead electrical connector.
6. Disconnect the Powertrain Control Module (PCM) electrical connector. 7. Disconnect the Heated
Oxygen Sensor (HO2S) connectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Service and Repair > Page 5100
8. Disconnect the electrical connectors.
^ ignition coil
^ radio ignition interference capacitor
9. Disconnect the electrical connectors.
^ Engine Coolant Temperature (ECT) sensor
^ water temperature indicator sender unit
10. Disconnect the backpressure transducer electrical connector.
11. Disconnect the Camshaft Position (CMP) sensor electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Fuel Injector Wiring
Harness > Component Information > Service and Repair > Page 5101
12. Disconnect the Crankshaft Position (CKP) sensor electrical connector. 13. Remove the wiring
harness from the vehicle.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service Precautions
Fuel Line Coupler: Service Precautions
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
^ THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND CONDENSED FUEL
VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL PRESENTS THE
DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND CABLE FROM
THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK OCCURRING,
POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID IS PRESENT
IN THE AREA.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings
Fuel Line Coupler: Service and Repair Push Connect Fittings
Fuel Line Removal Tool
SPECIAL SERVICE TOOL(S)
DISCONNECT
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel
Filter/Fuel Pressure Release
2. Disconnect the safety clip from the male hose.
3. Install the Fuel Line Disconnect Tool and push it into the fitting.
4. Separate the fittings.
^ Inspect for damage.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 5107
^ Clean the fittings.
CONNECT
1. Align the tube to the fitting and push until you hear a click.
NOTE: Lubricate the tube end with clean engine oil meeting Ford specification WSS-M2C153-G to
ease assembly.
2. Pull on the fitting to make sure it is fully engaged, then install the safety clip.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 5108
Fuel Line Coupler: Service and Repair R-Clip Fittings
DISCONNECT
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED.
CAUTION: Do not use any tools. The use of tools may cause a deformity in the clip components
which may cause fuel leaks.
1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel
Filter/Fuel Pressure Release 2. Remove the shipping tab by bending downward.
3. Spread the R-clip legs and push the clip into the fitting.
4. Separate the fitting from the tube.
CONNECT
1. Inspect the fitting and the tube for damage. Remove any dirt or obstructions. 2. Apply a light coat
of clean engine oil meeting Ford specification WSS-M2C153-G to the male tube end.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 5109
3. Insert the R-clip into the fitting.
4. Align the tube and the fitting.
5. Insert the tube into the fitting and push together until a click is heard.
6. Pull on the connection to make sure it is fully engaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 5110
Fuel Line Coupler: Service and Repair Spring Lock Couplings
SPECIAL SERVICE TOOL(S)
DISCONNECT
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE
PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY
OR A FIRE HAZARD.
1. Relieve the fuel pressure. For additional information, refer to Fuel Pressure Release. See: Fuel
Filter/Fuel Pressure Release
2. Remove the fuel tube clip.
3. Install the Spring Lock Coupler Tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 5111
4. Close and push the Spring Lock Coupler Tool into the open side of the cage.
5. Separate the fitting.
6. Remove the Spring Lock Coupler Tool.
CONNECT
1. Connect the fitting.
^ Inspect and clean both the coupling ends.
^ Lubricate the O-rings with clean engine oil meeting Ford specification WSS-M2C153-G.
^ Connect the fitting.
^ Pull on the fitting to make sure it is fully engaged.
^ Install the safety clip.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Push Connect Fittings > Page 5112
Fuel Line Coupler: Service and Repair Vapor Tube Fittings
DISCONNECT
1. Disconnect the battery ground cable. For additional information, refer to Battery.
WARNING: THE EVAPORATIVE EMISSION SYSTEM CONTAINS FUEL VAPOR AND
CONDENSED FUEL VAPOR. ALTHOUGH NOT PRESENT IN LARGE QUANTITIES, IT STILL
PRESENTS THE DANGER OF EXPLOSION OR FIRE. DISCONNECT THE BATTERY GROUND
CABLE FROM THE BATTERY TO MINIMIZE THE POSSIBILITY OF AN ELECTRICAL SPARK
OCCURRING, POSSIBLY CAUSING A FIRE OR EXPLOSION IF FUEL VAPOR OR FUEL LIQUID
IS PRESENT IN THE AREA.
2. Disconnect the vapor tube from the fitting.
1 Squeeze the fitting.
2 Disconnect the vapor tube from the fitting.
CONNECT
1. Inspect the fitting and the tube for damage. 2. Remove any dirt or obstructions.
3. Push the tube into the fitting until it snaps in place.
4. Pull on the connection to make sure the fitting is secure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Page 5113
Fuel Line Coupler: Tools and Equipment
Fuel Line Disconnect Tool
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations
Fuel Pressure Regulator: Locations
FUEL PUMP MODULE
Fuel Pump Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 5117
Fuel Pump Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 5118
Mechanical Returnless Fuel Pump Module (FPM)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 5119
Electronic Returnless Fuel Pump Module (FPM)
The Fuel Pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the
fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and
supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump
continuously refills the reservoir with fuel, and a check valve located in the manifold outlet
maintains system pressure when the fuel pump is not energized. A flapper valve located in the
bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial
fill.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 5120
Fuel Pressure Regulator: Description and Operation
FUEL PUMP MODULE
Fuel Pump Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 5121
Fuel Pump Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 5122
Mechanical Returnless Fuel Pump Module (FPM)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 5123
Electronic Returnless Fuel Pump Module (FPM)
The Fuel Pump (FP) module (Figure 66), (Figure 67) and (Figure 68) is a device that contains the
fuel pump and sender assembly. The fuel pump is located inside the FP module reservoir and
supplies fuel through the FP module manifold to the engine and FP module jet pump. The jet pump
continuously refills the reservoir with fuel, and a check valve located in the manifold outlet
maintains system pressure when the fuel pump is not energized. A flapper valve located in the
bottom of the reservoir allows fuel to enter the reservoir and prime the fuel pump during the initial
fill.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Description and Operation
Fuel Pressure Sensor/Switch: Description and Operation
FUEL RAIL PRESSURE SENSOR
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which
resistance changes with pressure. The electrical resistance of a strain gauge increases as
pressure increases, and decreases as pressure decreases. The varying resistance affects the
voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding
to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel
rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel
system. The differential fuel/intake manifold pressure together with measured fuel temperature
provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature
feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump
sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to
decrease.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Specifications
Fuel Pressure Test Port: Specifications
Fuel Pressure Relief Valve Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Technician Safety Information > Page 5132
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Page 5133
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Service Precautions > Page 5134
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel
supply line.
3. Remove the four bolts and the fuel supply line from the fuel supply manifold.
4. Remove the fuel supply line bracket bolt and the fuel supply line.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G, to aid installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Pulsation Damper: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL- RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Technician Safety Information > Page 5139
Fuel Pressure Pulsation Damper: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Page 5140
Fuel Pressure Pulsation Damper: Description and Operation
FUEL RAIL PULSE DAMPER
Pulse Damper
The fuel rail pulse damper (Figure 71) located on the fuel rail reduces fuel system noise caused by
the pulsing of the fuel injectors. The vacuum port located on the damper is connected to manifold
vacuum to avoid fuel spillage in the event the pulse damper diaphragm were to rupture. (The pulse
damper should not be confused with a fuel pressure regulator, it does not regulate fuel rail
pressure.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper >
Component Information > Service Precautions > Page 5141
Fuel Pressure Pulsation Damper: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL- RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the fuel injection supply manifold. For additional information, refer to Fuel Rail.
2. Remove the two bolts, the fuel pulse damper and the O-ring seals.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G, to aid installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Specifications
Fuel Pressure Test Port: Specifications
Fuel Pressure Relief Valve Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Technician Safety Information
Fuel Pressure Test Port: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Technician Safety Information > Page 5149
Fuel Pressure Test Port: Vehicle Damage Warnings
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 5150
Fuel Pressure Test Port: Description and Operation
PRESSURE TEST POINT
There is a pressure test point with a schrader fitting in the fuel rail that relieves fuel pressure and
measures the fuel injector supply pressure for service and diagnostic procedures. Before servicing
or testing the fuel system, read any CAUTION, WARNING, and HANDLING information. ON
VEHICLES NOT EQUIPPED WITH A SCHRADER VALVE, USE ROTUNDA FUEL PRESSURE
TEST KIT #134-ROO87 OR EQUIVALENT.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Service Precautions > Page 5151
Fuel Pressure Test Port: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect fuel
supply line.
3. Remove the four bolts and the fuel supply line from the fuel supply manifold.
4. Remove the fuel supply line bracket bolt and the fuel supply line.
INSTALLATION
1. To install, reverse the removal procedure.
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-ring
seals can cause the fuel system to leak. Do not reuse O-ring seals.
NOTE: Lubricate the new O-ring seals with Super Premium SAE 5W-30 Motor Oil, XO-5W30-QSP
or equivalent meeting Ford specification WSS-M2C153-G, to aid installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Fuel Pump Relay: Locations
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 5155
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 5156
Fuel Pump Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Specifications
Fuel Rail: Specifications
Fuel Injection Supply Manifold Bolts 25 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Technician Safety Information
Fuel Rail: Technician Safety Information
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Technician Safety Information > Page 5162
Fuel Rail: Vehicle Damage Warnings
CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply
manifold is used as a leverage device, damage may occur to the supply manifold. Care must be
taken when working around the supply manifold.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 5163
Fuel Rail: Description and Operation
The fuel injection supply manifold:
^ delivers fuel to the individual fuel injectors.
^ receives fuel from the fuel supply line.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 5164
Fuel Rail: Service and Repair
REMOVAL
WARNING:
^ DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN
WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY FLAMMABLE
MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
^ FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE
ENGINE IS NOT RUNNING. BEFORE WORKING ON OR DISCONNECTING ANY OF THE FUEL
LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE
RELIEVED. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL
INJURY.
CAUTION: This vehicle is equipped with a composite material fuel supply manifold. If the supply
manifold is used as a leverage device, damage may occur to the supply manifold. Care must be
taken when working around the supply manifold.
1. Remove the upper intake manifold. For additional information, refer to Engine. 2. Disconnect the
fuel line.
NOTE: After disconnecting the fuel line, plug the line to prevent leaks.
3. Disconnect the three LH fuel injector electrical connectors.
NOTE: One connector is shown, the other two are similar.
4. Disconnect the RH fuel injector electrical connector.
5. Remove the four bolts from the fuel supply line.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information
> Service Precautions > Page 5165
6. Disconnect the fuel pulse damper vacuum hose.
7. Remove the fuel injection supply manifold.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Specifications
Fuel Supply Line: Specifications
Fuel Supply Line Support Bracket bolt 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Specifications > Page 5169
Fuel Supply Line: Tools and Equipment
3/8" Fuel Line Remover
AST tool# 8013
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Specifications > Page 5170
Used for removing 3/8" fuel lines and feed lines from the fuel pump-sending unit.
- For R and R of Fuel and Feed Lines
- Quick line removal
- Gold-Anodized Aluminum Construction
- See Application Chart
- Included in the 8100, 8107 and #8110 Line Disconnect Sets.
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
This Tool is also available in the following kits:
8110 - 10-Pc. Line Disconnect Set
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Specifications > Page 5171
8107 - 7-Piece Line Disconnect Set
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Hose: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5181
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5182
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5183
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5184
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Hose: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5185
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Hose: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap
Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5191
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5192
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5193
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5194
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Hose: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5195
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Page 5196
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Page 5197
Fuel Filler Hose: Description and Operation
The fuel filler pipe check valve is an integral part of the fuel tank or the fuel filler pipe. It is intended
to prevent liquid fuel from re-entering the fuel filler pipe from the fuel tank on refueling or rollover
conditions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Page 5198
Fuel Filler Hose: Service and Repair
REMOVAL
1. Remove the fuel tank filler cap.
2. Remove the screws.
3. Remove the fuel tank filler pipe and the vent hose from the fuel tank and remove the fuel tank
filler pipe.
INSTALLATION
1. Install the fuel tank filler pipe and the vent hose.
1 Orient clamp bonding patch with top of the fuel tank.
2 Tighten the hose clamps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose >
Component Information > Technical Service Bulletins > Page 5199
2. Install the three fuel tank filler pipe screws.
3. Install the fuel tank filler cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Neck: Customer Interest Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5208
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5209
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5210
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5211
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > Customer Interest for Fuel Filler Neck: > 03-20-3 > Oct > 03 >
Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5212
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON
Fuel Filler Neck: All Technical Service Bulletins Emissions - MIL ON/DTC's Stored/Check Fuel Cap
Lamp ON
Article No. 03-20-3
10/13/03
DRIVEABILITY - MALFUNCTION INDICATOR LAMP
(MIL) ILLUMINATED WITH DTC'S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP
LAMP ILLUMINATED WITH DTC P0457
FORD: 1997-2000 CONTOUR 1997-2002 ESCORT 1997-2003 CROWN VICTORIA, MUSTANG,
TAURUS 1998-2003 ESCORT ZX2 2000-2003 FOCUS 2002-2003 THUNDERBIRD 1997 F-250
HD 1997-1999 F-250 LD 1997-2003 E SERIES, EXPEDITION, EXPLORER, F-150, RANGER,
WINDSTAR 1999-2003 F SUPER DUTY 2000-2003 EXCURSION 2001-2003 ESCAPE,
EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1997-1998 MARK VIII 1997-2002 CONTINENTAL 1997-2003 TOWN CAR 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD
MERCURY: 1997-1999 TRACER 1997-2000 MYSTIQUE 1997-2003 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2003 MOUNTAINEER
This article supersedes TSB 03-9-8 to update the vehicle lines and Service Procedures.
ISSUE Some vehicles may exhibit a Malfunction Indicator Lamp (MIL) illuminated with Diagnostic
Trouble Codes (DTCs) P0442, P0455, P0456, P0457 or P1442 or a "Check Fuel Cap" Lamp
illuminated with DTC P0457 for the Evaporative Emission System. This may be caused by loose or
leaking hoses, loose or broken fuel cap, a leak at the top of the fuel filler pipe neck, etc.
ACTION Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent, to locate
and repair leaks in the Evaporative Emission System. Refer to the following Service Procedure for
details.
Definitions of Acronyms
^ CVS Canister Vent Solenoid
^ DTC Diagnostic Trouble Code
^ EVAP Evaporative Emissions System
^ EVMV Electronic Vapor Management Valve
^ FTP Fuel Tank Pressure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5218
^ MIL Malfunction Indicator Lamp
^ NGS New Generation STAR Tester
^ PID Parameter Identifier WDS Worldwide Diagnostic System
SERVICE PROCEDURE
NOTE
THIS PROCEDURE SUPERSEDES ALL OTHER PROCEDURES PUBLISHED IN SERVICE
MANUALS AND TSB ARTICLES.
NOTE
MANY EVAP LEAKS ARE CAUSED BY A LOOSE OR FAULTY CAP. IF THE FUEL CAP IS
SUSPECT DURING VISUAL INSPECTION, DO NOT DISTURB THE FUEL CAP UNTIL THE
DIAGNOSTIC PROCEDURE IS COMPLETE. IF THE LEAK VERIFICATION FAILS, THE CAP
CAN BE REPOSITIONED OR REPLACED AND THE TEST REPEATED. THIS ACTION WILL
ISOLATE THE CAP FROM THE REST OF THE EVAP SYSTEM AS A POTENTIAL CONCERN. IF
DEBRIS ON THE SEALING SURFACE OF THE CAP APPEARS TO BE THE SOURCE OF THE
LEAK, CLEAN THE CAP AND REINSTALL.
OVERVIEW OF TEST PROCEDURES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5219
NOTE
SEE (FIGURE 1) AT END OF ARTICLE FOR TEST PROCEDURE FLOWCHART.
This TSB provides the following procedures:
^ Check the EVAP Canister Purge Valve (9C915) for a no flow condition
^ Locate a leak so that a repair can be performed
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5220
^ Verify repair by utilizing a metered air pressure test
EVAP CANISTER PURGE VALVE NO FLOW TEST
1. Using WDS Datalogger select the following PID's: EVAPVM # (or EVMV#), EVAPCV # and FTP.
2. Start the vehicle.
3. Close both the Canister Vent Solenoid (CVS) (EVAPCV # On or 100% duty cycle) and the EVAP
Canister Purge Valve (EVAPVM# Off or zero % duty cycle).
4. While monitoring the FTP PID, command open the EVAP Canister Purge Valve with the
EVAPVM# PID to 100% duty
5. If the FTP decreases and/or the RPM changes and/or the engine stalls, the test passed. Turn off
engine and proceed to test procedures below. Otherwise replace the EVAP Canister Purge Valve,
verify the repair by repeating the No Flow Test and return vehicle.
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
1. Disconnect the larger of two manifold vacuum lines at the EVAP Canister Purge Valve and cap it
at the EVAP Canister Purge Valve (see Figure 2).
2. Connect the Smoke Machine power cables to vehicle battery The "Power Indicator Lamp" should
be on indicating a good battery contact.
3. Position the selector valve on Rotunda's Smoke Machine Control Panel to "SMOKE".
4. Locate the vehicle's Evaporative Emission Service Test Port and remove the green cap. The
EVAP Service Test Port is located close to or on the EVAP Canister Purge Valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5221
WARNING
DO NOT REMOVE THE SCHRADER VALVE. REMOVING THE SCHRADER VALVE FROM THE
TEST PORT ON VEHICLES EQUIPPED WITH THE ELECTRONIC VAPOR MANAGEMENT
VALVE (9G641) AND/OR ELECTRONIC VAPOR MANAGEMENT VALVE & BRACKET
ASSEMBLY (9G683) (SEE FIGURE 3), OR EVAP CANISTER PURGE VALVE (9C915) AND/OR
EVAP CANISTER PURGE VALVE & BRACKET ASSEMBLY (9F933) (SEE FIGURE 2) WILL
PERMANENTLY DAMAGE THE VALVE.
5. Install the EVAP Emission Test Port Adapter that is provided with the Rotunda's Smoke Machine
to EVAP Canister Purge Valve test port.
NOTE
SPECIAL PROCEDURES HAVE BEEN DESIGNATED FOR WINDSTAR, LS, THUNDERBIRD &
PZEV FOCUS BECAUSE THEY HAVE A CHECK VALVE THAT WILL PREVENT SMOKE FROM
ENTERING THE FILLER NECK.
6. Connect black smoke hose nozzle tip to the EVAP Emission Test Port Adapter. For all except
Windstar, LS, Thunderbird & PZEV Focus Use NGS or WDS to close CVS. (CVS WILL REOPEN
AFTER NINE (9) MINUTES OF CONTINUOUS OPERATION).
7. For all except Windstar, LS, Thunderbird & PZEV Focus - Remove the fuel cap from the vehicle.
Depress remote starter button: Smoke will be introduced into the EVAP Emission System. Secure
the fuel cap once smoke is seen exiting from the fuel tank's neck area. For Windstar, LS,
Thunderbird & PZEV Focus, do not remove fuel cap. Depress starter button and introduce smoke to
system until it can be seen exiting the CVS (located by filler neck). Once smoke is seen, use NGS
or WDS to close CVS. (CVS WILL REOPEN AFTER NINE (9) MINUTES OF CONTINUOUS
OPERATION).
8. Press and release the remote starter button in intervals of approximately 15 seconds on and 15
seconds off. Use the halogen light provided with the Smoke Machine to look for smoke in the
engine compartment, EVAP hoses to EVAP Canister Purge Valve, CVS, carbon canister and area
around the fuel cap. Wiggle fuel vapor lines to check for leaks. Check for leaks in areas that are
difficult to access, such as connections on top of the tank where connections may be or inside
frame rails. Use the black light to ensure that there are no leaks. If a leak is detected, repair as
necessary. If the leak is not detected from the top, check under the bottom of vehicle. Inspect the
EVAP hoses running to the carbon canister, fuel filler neck, CVS, and EVAP Canister Purge Valve.
Go to LEAK VERIFICATION to verify any repair or if no leak is found.
LEAK VERIFICATION (METERED AIR SYSTEM)
1. Position the selector valve located on the Smoke Machine control panel to "METER".
2. Verify calibration of the flow meter by using the .020" calibrated leak orifice. To do this, insert air
supply hose (transparent hose) nozzle tip into appropriate EVAP System calibrated leak orifice
located on the front of the Smoke Machine panel.
3. TURN ON: Depress the remote starter button. Observe the position of the flow meter indicator
ball. Position the flow meter red pointer flag so it aligns with the measurement of the indicator ball.
Release the button and remove the air supply hose nozzle tip from the EVAP System calibrated
leak orifice.
NOTE
THIS FLOW METER CALIBRATION MEASUREMENT INDICATES THE VEHICLE PASS OR FAIL
CRITERIA BASED ON THE .020" EVAP SYSTEM LEAK STANDARD.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Neck >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Filler Neck: > 03-20-3 > Oct
> 03 > Emissions - MIL ON/DTC's Stored/Check Fuel Cap Lamp ON > Page 5222
4. Connect the transparent air supply hose nozzle tip into the EVAP Service Test Port adapter.
5. Use NGS or WDS Diagnostic tool to CLOSE the CVS.
6. Depress the remote starter button on the Rotunda's Smoke Leak Detector. The indicator ball in
the flowmeter will go all the way to the top indicating the system is being pressurized. Continue to
depress the remote starter button until the ball stops descending. Once the indicator ball has
stopped descending, observe if it is above or below the red indicator flag. If performing this
verification following a repair, go to Step 7. If performing this verification after performing the
SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE), go to Step 8.
7. Leak Verification After Repair
a. If the measurement is below the indicator flag the system has passed. The test procedure is
complete. Remove the Smoke Machine Test equipment from the vehicle and reconnect the large
EVAP Canister Purge Valve manifold vacuum hose and the test port's green cap.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
8. Leak Verification After Passing SYSTEM LEAK CHECK (SMOKE TEST PROCEDURE)
a. If the measurement is below the indicator flag the system has passed, go to Step 9.
b. If the measurement is above the indicator flag, repeat SYSTEM LEAK CHECK (SMOKE TEST
PROCEDURE).
9. Using WDS Datalogger or NGS select the FTPV PID.
10. Remove Fuel Cap and turn the vehicle's ignition switch to the run position and check the FTPV
PID.
11. The nominal value for the FTPV PID is 2.6V. If the value is greater than 2.8V or less than 2.4V,
the FTP sensor is out of range and should be replaced. Verify the repair by checking to see if the
new sensor is in range. For all except Windstar, LS, Thunderbird & PZEV Focus - if the sensor is
within range, the concern is no longer present. (Windstar, LS, Thunderbird & PZEV Focus go to
Step 12.)
12. For Windstar, LS, Thunderbird & PZEV Focus only verify that filler neck clamps are in good
working order and tightened. Repair as necessary. If no problem is found with clamps, replace the
fuel cap.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 03-9-8 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Testing and Inspection
Fuel Gauge Sender: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Testing and Inspection > Page 5226
Fuel Gauge Sender: Service and Repair
Service and Repair
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component
Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications
Idle Air Control Valve: Specifications
Idle Air Control Valve Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5233
Idle Air Control Valve: Description and Operation
IDLE AIR CONTROL VALVE
Nippondenso Idle Air Control (IAC) Valve Assembly
Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter
The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed
and provides a dashpot function. The IAC valve assembly meters intake air around the throttle
plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the
desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle.
The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The
PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the
desired rpm.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5234
Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors
On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount
of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low
speed and light load conditions.
NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED.
The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the
internal diode is measured in crossed terminal position with a digital multimeter, there will be an
incorrect or negative reading. It is important that the mating component and harness connectors
correctly oriented. Diagnostic procedures emphasize this importance.
The PCM uses the IAC valve assembly to control:
^ No touch start
^ Cold engine fast idle for rapid warm-up
^ Idle (corrects for engine load)
^ Stumble or stalling on deceleration (provides a dashpot function)
^ Over-temperature idle boost.
^ Air Assist to Injectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5235
Idle Air Control Valve: Testing and Inspection
1. Open the hood. 2. Verify the condition by operating the vehicle for a short time.
NOTE: ^
Key symptom is elevated idle speed while noise is occurring.
^ "Snapping" the throttle can induce the noise.
3. Inspect the IAC valve. If physical evidence of contamination exists, install a new IAC valve. 4.
While the noise is occurring, either place an Engine EAR probe near the IAC valve and the inlet
tube, or create a 6.35 mm (0.25 in) - 12.7 mm
(0.50 in) air gap between the inlet tube and the clean air tube. If the IAC valve is making the noise,
install a new IAC valve.
5. Test the vehicle for normal operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Air Control Valve <--> [Idle
Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 5236
Idle Air Control Valve: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Disconnect the idle air control (IAC) valve electrical connector.
4. Remove the IAC valve and discard the gasket.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Install a new IAC valve gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 5240
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump.
The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel
ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the
magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the
switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset
before restarting the vehicle. Refer to the Owner Guide for the location of the IFS.
Inertia Fuel Shutoff (IFS) Switch
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Inertia Fuel Shutoff Switch >
Component Information > Locations > Page 5241
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery. For additional information, refer to Battery.
2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical
connector.
3. Remove the bolts and remove the IFS switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component
Information > Service and Repair
Intake Air Duct: Service and Repair
REMOVAL
1. Remove the engine appearance cover.
^ Disconnect the speed control cable (if equipped).
^ Remove the bolts.
2. Remove the air cleaner outlet tube.
1 Unclip the wire harness
2 Disconnect the crankcase ventilation tubes.
3 Loosen the air cleaner outlet tube clamps and remove the air cleaner outlet tube.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Make sure the screw clamps do not interfere with the throttle body cam.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Powertrain Control Module Power Relay: Locations
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5248
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Powertrain Control Module Power
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations > Page 5249
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations
Fuel Pump Relay: Locations
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5254
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 5255
Fuel Pump Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations
Powertrain Control Module Power Relay: Locations
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 5259
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery
and Air Induction > Powertrain Control Module Power Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations > Page 5260
Powertrain Control Module Power Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications
Mass Air Flow Sensor: Specifications
Mass Air Flow Sensor Nuts And Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications >
Page 5265
Mass Air Flow Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications >
Page 5266
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications >
Page 5267
Mass Air Flow Sensor: Description and Operation
MASS AIR FLOW SENSOR
Typical Mass Air Flow (MAF) Sensor
The Mass Air Flow (MAF) sensor uses a hot wire sensing element to measure the amount of air
entering the engine. Air passing over the hot wire causes it to cool. This hot wire is maintained at
200°C (392°F) above ambient temperature as measured by a constant cold wire (Figure 36). If the
hot wire electronic sensing element must be replaced, then the entire assembly must be replaced.
Replacing only the element may change the air flow calibration.
The current required to maintain the temperature of the hot wire is proportional to the air mass flow.
The MAF sensor then outputs an analog voltage signal to the PCM proportional to the intake air
mass. The PCM calculates the required fuel injector pulse width in order to provide the desired
air/fuel ratio (Figure 37). This input is also used in determining transmission Electronic Pressure
Control (EPC), shift and torque converter clutch scheduling.
Some MAF sensors have Integrated Bypass Technology (IBT) with an integrated Intake Air
Temperature (IAT) sensor. The present applications with IBT are: Focus, Escort (4V), 2.0L Cougar,
Escape, Taurus/Sable, Windstar, Explorer/Mountaineer and E-Series.
The MAF sensor is located between the air cleaner and the throttle body or inside the air cleaner
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Mass Air Flow Sensor <--> [Air Flow Meter/Sensor] > Component Information > Specifications >
Page 5268
Mass Air Flow Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
3. Loosen the air cleaner outlet tube clamp and position aside.
4. Remove the four bolts and the MAF sensor.
CAUTION: The MAF sensor electronics module and body are calibrated as a unit and must be
replaced as a unit. Do not tamper with the sensing elements located in the air flow bypass of the
MAF body.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Description and Operation
Fuel Pressure Sensor/Switch: Description and Operation
FUEL RAIL PRESSURE SENSOR
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 31) is a diaphragm strain gauge device in which
resistance changes with pressure. The electrical resistance of a strain gauge increases as
pressure increases, and decreases as pressure decreases. The varying resistance affects the
voltage drop across the sensor terminals and provides electrical signals to the PCM corresponding
to pressure.
Strain gauge type sensors are considered passive sensors. A passive sensor is connected to a
voltage divider network so that varying the resistance of the passive sensor causes a variation in
total current flow.
Voltage that is dropped across a fixed resistor in series with the sensor resistor determines the
voltage signal at the PCM. This voltage signal is equal to the reference voltage minus the voltage
drop across the fixed resistor.
The FRP sensor measures the pressure of the fuel near the fuel injectors. This signal is used by
the PCM to adjust the fuel injector pulse width and meter fuel to each engine combustion cylinder.
Fuel Rail Pressure (FRP) Sensor
The Fuel Rail Pressure (FRP) sensor (Figure 32) senses the pressure difference between the fuel
rail and the intake manifold. The return fuel line to the fuel tank has been deleted in this type of fuel
system. The differential fuel/intake manifold pressure together with measured fuel temperature
provides an indication of the fuel vapors in the fuel rail. Both differential pressure and temperature
feedback signals are used to control the speed of the fuel pump. The speed of the fuel pump
sustains fuel rail pressure which preserve fuel in its liquid state. The dynamic range of the fuel
injectors increase because of the higher rail pressure, which allows the injector pulse width to
decrease.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5275
Inertia Fuel Shutoff Switch: Description and Operation
Inertia Fuel Shutoff (IFS) Switch
Inertia Fuel Shutoff (IFS) Switch
The Inertia Fuel Shutoff (IFS) switch (Figure 72) is used in conjunction with the electric fuel pump.
The purpose of the IFS switch is to shut off the fuel pump if a collision occurs. It consists of a steel
ball held in place by a magnet. When a sharp impact occurs, the ball breaks loose from the
magnet, rolls up a conical ramp and strikes a target plate which opens the electrical contacts of the
switch and shuts off the electric fuel pump. Once the switch is open, it must be manually reset
before restarting the vehicle. Refer to the Owner Guide for the location of the IFS.
Inertia Fuel Shutoff (IFS) Switch
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Inertia Fuel Shutoff Switch > Component Information > Locations > Page 5276
Inertia Fuel Shutoff Switch: Service and Repair
REMOVAL
1. Disconnect the battery. For additional information, refer to Battery.
2. Access the Inertia Fuel Shutoff (IFS) switch on the RH toe board and disconnect the electrical
connector.
3. Remove the bolts and remove the IFS switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations
Throttle Position Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 5280
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > PCM Inputs >
Page 5283
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Description and Operation > Page 5284
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Remove the Throttle Position (TP) sensor.
1 Disconnect the TP sensor electrical connector.
2 Remove the sensor.
NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications
Throttle Body: Specifications
Throttle Body Bolts 7 Nm
Throttle Body-to-upper Intake Manifold Bolts 8 - 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Technician Safety Information
Throttle Body: Technician Safety Information
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service Precautions > Technician Safety Information > Page 5290
Throttle Body: Vehicle Damage Warnings
CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or
possible damage to the throttle body may occur.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body Housing
Throttle Body: Description and Operation Throttle Body Housing
THROTTLE BODY HOUSING
The throttle body housing assembly is a single piece of aluminum casting with an air passage and
a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed)
position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return
stop prevents the throttle plate from contacting the bore and sticking closed. The setting also
establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate
air flow, a special coating is applied to the throttle plate and bore to help seal this area. This
sealant/coating also makes the throttle body resistant to engine intake sludge accumulation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body Housing > Page 5293
Throttle Body: Description and Operation Throttle Body System Overview
THROTTLE BODY SYSTEM OVERVIEW
The throttle body system meters air to the engine during idle, part throttle, and Wide Open Throttle
(WOT) conditions. The throttle body system consists of an Idle Air Control (IAC) valve assembly,
idle air orifice, single or dual bores with butterfly valve throttle plates and a Throttle Position (TP)
sensor. One other source of idle air flow is the Positive Crankcase Ventilation (PCV) system. The
combined idle air flow (from idle air orifice IAC flow and PCV flow) is measured by the MAF sensor
on all applications.
During idle, the throttle body assembly provides a set amount of air flow to the engine through the
idle air passage and PCV valve. The IAC valve assembly provides additional air when commanded
by the Powertrain Control Module (PCM) to maintain the proper engine idle speed under varying
conditions. The IAC valve assembly mounts directly to the throttle body assembly in most
applications, but is remote-mounted to the intake manifold in some applications. Idle speed is
controlled by the PCM and cannot be adjusted.
NOTE: The traditional idle air adjust procedure as well as throttle return screw are no longer used
on OBD II applications.
Throttle rotation is controlled by a cam/cable linkage to slow the initial opening rate of the throttle
plate. The TP sensor monitors throttle position and provides an electrical signal to the PCM. Some
throttle body applications provide an air supply channel upstream of the throttle plate to provide
fresh air to the Positive Crankcase Ventilation (PCV) or IAC systems. Other throttle body
applications provide individual vacuum taps downstream of the throttle plate for PCV return,
Exhaust Gas Recirculation (EGR), Evaporative Emission (EVAP), and miscellaneous control
signals.
Throttle Body System Hardware
The major components of the throttle body assembly include the TP sensor, IAC valve assembly,
and throttle body housing assembly.
Throttle Position Sensor
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Idle Air Control Valve
Nippondenso Idle Air Control (IAC) Valve Assembly
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body Housing > Page 5294
Hitachi Idle Air Control (IAC) Valve Assembly With Vent/Filter
The Idle Air Control (IAC) valve assembly (Figure 117) and (Figure 118) controls engine idle speed
and provides a dashpot function. The IAC valve assembly meters intake air around the throttle
plate through a bypass within the IAC valve assembly and throttle body. The PCM determines the
desired idle speed or bypass air and signals the IAC valve assembly through a specified duty cycle.
The IAC valve responds by positioning the IAC valve to control the amount of bypassed air. The
PCM monitors engine rpm and increases or decreases the IAC duty cycle in order to achieve the
desired rpm.
Hitachi Idle Air Control (IAC) Valve Assembly With Air-Assist Injectors
On applications with air-assisted injectors, the IAC valve (Figure 119) also supplies a small amount
of air into the path of the fuel injectors. The jet of air causes an increase in fuel atomization at low
speed and light load conditions.
NOTE: The IAC Valve Assembly is NOT ADJUSTABLE and CANNOT BE CLEANED.
The IAC valve (part of throttle body assembly) has an internal diode on some applications. If the
internal diode is measured in crossed terminal position with a digital multimeter, there will be an
incorrect or negative reading. It is important that the mating component and harness connectors
correctly oriented. Diagnostic procedures emphasize this importance.
The PCM uses the IAC valve assembly to control:
^ No touch start
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Throttle Body Housing > Page 5295
^ Cold engine fast idle for rapid warm-up
^ Idle (corrects for engine load)
^ Stumble or stalling on deceleration (provides a dashpot function)
^ Over-temperature idle boost.
^ Air Assist to Injectors.
Throttle Body Housing
The throttle body housing assembly is a single piece of aluminum casting with an air passage and
a butterfly throttle plate with linkage mechanisms. When the throttle plate is in the idle (or closed)
position, the throttle lever arm should be in contact with the Throttle Return Stop. The throttle return
stop prevents the throttle plate from contacting the bore and sticking closed. The setting also
establishes the amount of air flow between the throttle plate and bore. To minimize the closed plate
air flow, a special coating is applied to the throttle plate and bore to help seal this area. This
sealant/coating also makes the throttle body resistant to engine intake sludge accumulation.
Typical Attention Decal Locations
Features of the Throttle Body Assembly include:
1. Idle Air Control (IAC) valve assembly mounted directly to the throttle body assembly (some
vehicles). 2. A pre-set stop to locate the WOT position. 3. An air supply channel upstream of the
throttle plate to provide fresh air to the PCV system (some vehicles only). 4. Individual vacuum taps
for PCV, EGR, Evaporative Emission (EVAP) and miscellaneous control signals (some vehicles
only). 5. PCV air return (it applicable). 6. A throttle body-mounted Throttle Position (TP) sensor. 7.
A sealant/coating on the throttle bore and throttle plate makes the throttle body air flow tolerant to
engine intake sludge accumulation. These
throttle body assemblies MUST NOT BE CLEANED and have a white/black attention decal (Figure
116) advising not to clean.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Description and Operation > Page 5296
Throttle Body: Service and Repair
REMOVAL
WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY
TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENTS. HIGHLY
FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
CAUTION: Throttle body bore and plate area have a special coating and cannot be cleaned, or
possible damage to the throttle body may occur.
1. Remove the air cleaner outlet tube.
2. Disconnect the Throttle Position (TP) sensor electrical connector.
3. Disconnect the accelerator cable and the speed control cable (if equipped).
4. Remove the throttle body.
NOTE: Discard the throttle body gasket.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications
Throttle Cable/Linkage: Specifications
Accelerator Cable Bracket To Coil Bracket Nut 8 - 10 Nm
Accelerator Cable Bracket Stud Bolt 16 - 24 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 5300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Specifications > Page 5301
Throttle Cable/Linkage: Description and Operation
The accelerator cable is controlled by an accelerator pedal and shaft. The pedal and shaft should
travel smoothly from the idle to wide-open throttle positions. Failure to return or hesitation on return
to the idle position must not occur.
Surrounding components such as wiring, hoses, sound insulator and floor covering must not
contact the sliding inner member of the accelerator cable or the accelerator pedal and shaft.
The speed control speedometer cable and the accelerator cable are attached at the throttle lever
on the throttle body.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Throttle Cable/Linkage: Initial Inspection and Diagnostic Overview
NOTE: Care should be exercised when performing service on or around the accelerator pedal
linkage and controls.
1. Inspect the accelerator pedal and shaft and attaching linkage for damage or distortion which
would bind or limit accelerator travel. 2. Inspect the accelerator cable for kinks or fraying which may
cause bending. 3. Inspect the engine idle speed adjustment to make sure of the correct idle speed
specification after any accelerator linkage adjustment or repair. 4. Inspect throttle body for
excessive wear or damage.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 5304
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Testing and Inspection > Page 5305
Throttle Cable/Linkage: Service and Repair
REMOVAL
1. Remove the screws and the accelerator control splash shield.
2. Disconnect the accelerator cable from the throttle body.
3. Disconnect the accelerator cable from the intake manifold.
1 Remove the screw.
2 Disconnect the accelerator cable from the intake manifold.
4. From inside the vehicle, disconnect the accelerator cable from the accelerator pedal and shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Testing and Inspection > Page 5306
5. Collapse the clips at the dash panel and push the accelerator cable through the dash panel into
the engine compartment and remove the accelerator
cable.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations
Throttle Position Sensor: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 5310
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > PCM Inputs
Throttle Position Sensor: Description and Operation PCM Inputs
THROTTLE POSITION SENSOR
Typical Throttle Position (TP) Sensor
The Throttle Position (TP) sensor (Figure 42) is a rotary potentiometer sensor that provides a
signal to the PCM that is linearly proportional to the throttle plate/shaft position. The sensor housing
has a three-blade electrical connector that may be gold plated. The gold plating increases
corrosion resistance on terminals and increases connector durability. The TP sensor is mounted on
the throttle body. As the TP sensor is rotated by the throttle shaft, four operating conditions are
determined by the PCM from the TP. Those conditions are closed throttle (includes idle or
deceleration), part throttle (includes cruise or moderate acceleration), wide open throttle (includes
maximum acceleration or de-choke on crank), and throttle angle rate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > PCM Inputs > Page 5313
Throttle Position Sensor: Description and Operation Intake Air Systems
THROTTLE POSITION SENSOR
The TP sensor monitors throttle position and provides an electrical signal to the PCM. It is
monitored by the On-Board Diagnostic (OBD) II system for component integrity, system
functionality, and faults that can cause emissions levels to exceed standards set in government
regulations. For additional information on the TP sensor, refer to Electronic EC System
Hardware-PCM Inputs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Description and Operation > Page 5314
Throttle Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the accelerator control snow shield.
3. Remove the Throttle Position (TP) sensor.
1 Disconnect the TP sensor electrical connector.
2 Remove the sensor.
NOTE: The 4.0L (SOHC) is shown, the 4.0L push rod is similar.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Valve > Component Information > Description and Operation
Variable Induction Control Valve: Description and Operation
INTAKE MANIFOLD TUNING VALVE (IMTV)
Intake Manifold Tuning Valve (IMTV)
3.0L LS6 Intake Air System
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Valve > Component Information > Description and Operation > Page 5319
4.6L E/F-Series Intake Air System
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Variable Induction System >
Variable Induction Control Valve > Component Information > Description and Operation > Page 5320
5.4L (4) Intake Air System
The Intake Manifold Tuning Valve (IMTV) (Figure 107) is a motorized actuated unit mounted
directly to the intake manifold. The IMTV actuator controls a shutter device attached to the actuator
shaft. There is no monitor input to the PCM with this system to indicate shutter position.
The motorized IMTV unit will not be energized below approximately 2600 rpm or higher on some
vehicles. The shutter will be in the closed position not allowing airflow blend to occur in the intake
manifold. Above approximately 2600 rpm or higher, the motorized unit will be energized. The
motorized unit will be commanded on by the PCM initially at a 100 percent duty cycle to move the
shutter to the open position and then falling to approximately 50 percent to continue to hold the
shutter open.
1. The PCM uses the TP sensor and CKP signals to determine activation of the IMTV system.
There must be a positive change in voltage from
the TP sensor along with the increase in rpm to open the shutter.
2. The PCM uses the information from the input signals to control the IMTV. 3. When commanded
on by the PCM, the motorized actuator shutter opens up the end of the vertical separating wall at
high engine speeds to
allow both sides of the manifold to blend together.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order: Specifications
Coil Terminal-To-Cylinder Relationship
Firing order...........................................................................................................................................
..................................................................1-4-2-5-3-6
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications > Page 5325
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor, Stud Bolt 19 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 5333
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 5334
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 5335
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the CMP sensor electrical connector.
2 Remove the CMP sensor stud bolt.
3 Remove the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 5339
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Description and Operation > Electronic Engine Controls
Crankshaft Position Sensor: Description and Operation Electronic Engine Controls
The CKP sensor:
^ sends the PCM a signal indicating crankshaft position.
^ is essential for calculating spark timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Description and Operation > Electronic Engine Controls > Page 5342
Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel)
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Description and Operation > Page 5343
Crankshaft Position Sensor: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Crankshaft Position (CKP) sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor
has wear tabs that will wear off after several engine revolutions.
^ Be sure sensor wiring is routed away from the battery cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions
Ignition Cable: Service Precautions
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
^ Be sure to orient the spark plug boots so the spark plug wires do not contact the exhaust
manifold.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions > Page 5347
Ignition Cable: Service and Repair
Spark Plug Wire Remover
SPECIAL SERVICE TOOL(S)
REMOVAL
CAUTION:
^ Spark plug wires must be connected correctly. Mark the spark plug wires before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
1. With a twisting motion, use the special tool to pull the spark plug wire off the spark plug.
2. Squeeze the locking tabs and twist while pulling upward to remove the spark plug wires from the
ignition coil.
3. Remove the spark plug wires.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Service
Precautions > Page 5348
1. To install, reverse the removal procedure.
CAUTION: Be sure to orient the spark plug boots so the spark plug wires do not contact the
exhaust manifold.
NOTE: Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or
equivalent meeting Ford specification ESE-M1C171-A to the inside of the spark plug and ignition
coil boots of the spark plug wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Mechanical Specifications
Ignition Coil: Mechanical Specifications
Ignition Coil Bolts 6 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5353
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5354
Ignition Coil: Service Precautions
CAUTION:
^ Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire
locations before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5355
Ignition Coil: Description and Operation
Coil Pack
Horizontal Connector Six Tower Coil Pack
Series 5 Six Tower Coil Pack
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5356
Four - Tower Coil Packs
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5357
Series 5 Four Tower Coil Pack
Coil packs come in four tower, Series 5 four tower, six-tower horizontal connector and Series 5 Six
tower models. Two adjacent coil towers share a common coil and are called a matched pair. For
six-tower coil pack (six cylinder) applications the matched pairs are 1 and 5, 2 and 6, and 3 and 4
(Figure 56)and (Figure 57). For four-tower coil pack (four cylinder) applications the matched pairs
are 1 and 4, and 2 and 3 (Figure 58) and (Figure 59).
When the coil is fired by the PCM, spark is delivered through the matched pair towers to their
respective spark plugs. The spark plugs are fired simultaneously and are paired so that as one fires
on the compression stroke, the other spark plug fires on the exhaust stroke. The next time the coil
is fired the situation is reversed. The next pair of spark plugs fire according to the engine firing
order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Page 5358
Ignition Coil: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Disconnect the ignition coil electrical connections.
1 Squeeze the locking tabs and twist while pulling upward to disconnect the six spark plug wires.
CAUTION: ^
Spark plug wires must be connected to the correct ignition coil terminal. Mark spark plug wire
locations before removing them.
^ It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to
the spark plug wire.
2 Disconnect the ignition coil electrical connector.
3. Remove the ignition coil.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
Apply Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A or equivalent
meeting Ford specification ESE-M1C171-A to the inside of the spark plug wire coil boots.
^ Be sure to reinstall the radio ignition interference capacitor under the correct ignition coil
mounting bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Specifications
Knock Sensor: Specifications
Knock Sensor Bolt 25 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Specifications > Page 5362
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Specifications > Page 5363
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Specifications > Page 5364
Knock Sensor: Service and Repair
REMOVAL
1. Remove the lower in take manifold. For additional information, refer to Engine.
2. Remove the knock sensor.
1 Remove the bolt.
2 Remove the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications
Camshaft Position Sensor: Specifications
Camshaft Position Sensor, Stud Bolt 19 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 5369
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 5370
Camshaft Position Sensor: Description and Operation
CAMSHAFT POSITION SENSOR
The Camshaft Position (CMP) sensor detects the position of the camshaft. The CMP sensor
identifies when piston No.1 is on its compression stroke. A signal is then sent to the Powertrain
Control Module (PCM) and used for synchronizing the firing of sequential fuel injectors. The Coil
On Plug (COP) Ignition applications also use the CMP signal to select the proper ignition coil to
fire. The input circuit to the PCM is referred to as the CMP input or circuit.
Typical Hall-Effect Sensor
Typical Variable Reluctance Sensor
There are two types of CMP sensors: the three pin connector Hall-effect type sensor (Figure 22)
and the two pin connector variable reluctance sensor (Figure 23).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 5371
Camshaft Position Sensor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Camshaft Position (CMP) sensor.
1 Disconnect the CMP sensor electrical connector.
2 Remove the CMP sensor stud bolt.
3 Remove the camshaft position sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position Sensor Bolts 10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 5375
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls
Crankshaft Position Sensor: Description and Operation Electronic Engine Controls
The CKP sensor:
^ sends the PCM a signal indicating crankshaft position.
^ is essential for calculating spark timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Description and Operation > Electronic Engine Controls > Page
5378
Crankshaft Position Sensor: Description and Operation Standard Models (Non BI-Fuel)
CRANKSHAFT POSITION SENSOR (INTEGRATED IGNITION SYSTEMS)
Three Different Types Of Crankshaft Position (CKP) Sensors
The Crankshaft Position (CKP) sensor is a magnetic transducer mounted on the engine block
adjacent to a pulse wheel located on the crankshaft. By monitoring the crankshaft mounted pulse
wheel, the CKP is the primary sensor for ignition information to the Powertrain Control Module
(PCM). The trigger wheel has a total of 35 teeth spaced 10 degrees apart with one empty space for
a missing tooth. The 6.8L ten cylinder pulse wheel has 39 teeth spaced 9 degrees apart and one 9
degree empty space for a missing tooth. By monitoring the trigger wheel, the CKP indicates
crankshaft position and speed information to the PCM. By monitoring the missing tooth, the CKP is
also able to identify piston travel in order to synchronize the ignition system and provide a way of
tracking the angular position of the crankshaft relative to fixed reference (Figure 25).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Description and Operation > Page 5379
Crankshaft Position Sensor: Service and Repair
REMOVAL
NOTE: The 5.0L is shown, the 4.0L SOHC and the 4.0L (push rod) engines are similar.
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the Crankshaft Position (CKP) sensor.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
4.0L SOHC and 4.0L (push rod) CKP sensors need to be touching the damper. The CKP sensor
has wear tabs that will wear off after several engine revolutions.
^ Be sure sensor wiring is routed away from the battery cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
> Page 5385
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Removal
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
> Page 5386
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the bearing and the gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition
Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
> Page 5387
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Note: Use a new ignition switch lock cylinder.
Follow the removal procedure in reverse order. ^
Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Specifications
Knock Sensor: Specifications
Knock Sensor Bolt 25 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Specifications > Page 5391
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Specifications > Page 5392
Knock Sensor: Description and Operation
Knock Sensor
Two Types Of Knock Sensor (KS)
The Knock Sensor (KS) (Figure 35) is a tuned accelerometer on the engine which converts engine
vibration to an electrical signal. The PCM uses this signal to determine the presence of engine
knock and to retard spark timing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Specifications > Page 5393
Knock Sensor: Service and Repair
REMOVAL
1. Remove the lower in take manifold. For additional information, refer to Engine.
2. Remove the knock sensor.
1 Remove the bolt.
2 Remove the knock sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Spark Plug Gap
Spark Plug: Specifications
Spark Plug Gap 1.3 - 1.4 mm
RH Original Spark Plug AGRF22PG
LH Original Spark Plug AGRF22P
New Spark Plug (Either Side) AGSF22PP
Spark Plugs 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Spark Plug Gap > Page 5398
Spark Plug: Specifications
Spark Plug Gap 1.3 - 1.4 mm
RH Original Spark Plug AGRF22PG
LH Original Spark Plug AGRF22P
New Spark Plug (Either Side) AGSF22PP
Spark Plugs 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 5399
Spark Plug: Application and ID
RH Original Spark Plug Type ..............................................................................................................
.............................................................. AGRF22PG LH Original Spark Plug Type ............................
....................................................................................................................................................
AGRF22P New Spark Plug Type (Either Side) ...................................................................................
................................................................................. AGSF22PP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 5400
Spark Plug: Service and Repair
REMOVAL
1. Remove the spark plug wires. For additional information, refer to Ignition Cable.
2. Remove the spark plugs.
NOTE: ^
Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
^ If an original spark plug is reused, make sure it is installed in the same cylinder it was taken from.
New spark plugs can be used in any cylinder.
3. Inspect the spark plugs.
4. Use a suitable spark plug gap tool to check and adjust the spark plug gap.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 5407
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 5408
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 5409
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5412
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5413
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5414
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5415
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5416
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5417
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5418
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5419
Pressure Regulating Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5420
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5421
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5422
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5423
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5424
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5425
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5426
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 5427
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 5428
Pressure Regulating Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 5429
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 5430
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 5431
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications
Shift Interlock Solenoid: Specifications
Shift Lock Actuator Bolts 62.5-98 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications > Page 5435
Shift Interlock Solenoid: Service and Repair
Removal
1. Remove the steering column assembly.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced.
Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
Shift Solenoid: Locations
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Page 5439
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Page 5440
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Page 5441
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5444
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5445
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5446
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5447
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5448
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5449
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5450
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5451
Shift Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5452
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5453
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5454
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5455
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5456
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5457
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 5458
Diagram 29-4
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5459
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5460
Shift Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5461
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5462
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Page 5463
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Specifications > Page 5467
Torque Converter Clutch Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Information > Specifications > Page 5468
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Specifications > Page 5469
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Specifications > Page 5470
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5473
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5474
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5475
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5476
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Information > Diagrams > Diagram Information and Instructions > Page 5477
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5478
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5480
Torque Converter Clutch Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5481
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5482
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5483
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5484
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5485
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5486
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5487
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 5488
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 5489
Torque Converter Clutch Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 5490
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 5491
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Diagrams > Page 5492
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Specifications
Transfer Case Actuator: Specifications
Transfer case shift motor bolts
..............................................................................................................................................................
10 Nm (89 inch lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions
Transfer Case Actuator: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5499
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5500
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5501
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5502
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5503
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5504
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5505
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5506
Transfer Case Actuator: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5507
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5508
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5509
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5510
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5511
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5512
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 5513
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Page 5514
Transfer Case Actuator: Service and Repair
Removal and Installation
1. With the vehicle in the NEUTRAL position, raise and support the vehicle.
2. Remove the heat shield.
3. Disconnect the electrical connector.
4. Remove the coil wire from the electrical connector.
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> Diagrams > Page 5515
1. Remove the connector interlock. 2. Remove the coil wire pin.
- Use the proper electrical connector pin remover.
5. Remove the rear output shaft speed sensor.
- Carefully remove the sensor from the transfer case.
6. Remove the four bolts and the transfer case shift motor.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Page 5516
7. Remove the front output shaft speed sensor.
- Carefully remove the sensor from transfer case.
8. NOTE: Make sure the motor mounting surfaces are clean.
Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case.
9. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information >
Locations > Page 5522
Overdrive Indicator Lamp: Description and Operation
Overdrive (O/D) Off
The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function
indicator will also flash off and on if a transmission
malfunction is detected.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Locations > Page
5526
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D)
position.
- Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents
counterclockwise (D) position).
3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever.
4. Center the pointer in the middle of the (D) position.
- Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and
compare with the transmission settings.
- Readjust if necessary.
7. Install the upper instrument panel steering column cover.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and Repair
Control Module: Service and Repair
Removal
1. Remove the transmission control switch (TCS).
1. Remove the TCS cover. 2. Remove the TCS.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5545
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5546
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5547
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5548
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5549
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5550
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5551
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5552
Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5553
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5554
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5555
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5556
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5557
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5558
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Diagram Information and Instructions > Page 5559
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Page 5560
Control Module: Description and Operation
The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between
three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any
speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake
depressed and the transmission must be in NEUTRAL.
The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect
the speed of the front and rear driveshafts. This input is used by the generic electronic module
(GEM) primarily to control A4WD operation.
The throttle position output signal is provided to the GEM from the powertrain control module
(PCM). This signal is used by the GEM in controlling the A4WD clutch.
The shift motor sense plate an integral part of the electric shift motor informs the GEM to the
position of the transfer case.
The digital TR sensors are located on the LH side of the transmission; these sensors inform the
GEM when the transmission is in the neutral position.
The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam
which moves the mode fork and range fork within the transfer case between the HIGH range
(A4WD 4HIGH) and LOW range positions.
The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts
the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes.
The solid state clutch relay is used to activate the A4WD clutch within the transfer case.
System Function
Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM
varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under
cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of
time the clutch is turned on) which allows for the slight difference between the front and rear
driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the
following conditions the GEM will increase the duty cycle in order to prevent or control slip:
^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position).
Feature inputs:
^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch
(manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^
Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate
position inputs A B C D.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential
when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4
shift motor relay outputs.
Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and
outputs needed by the GEM to execute a change between any of these modes. Feature inputs:
^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD
mode switch.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential
when relay is off).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Page 5561
^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated).
When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h
(3 mph) the brake is applied and the transmission is in NEUTRAL.
Feature inputs:
^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^
Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage
when brake is depressed open circuit when not activated). ^ Digital transmission range sensor
(ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input
(manual transmission only).
Feature outputs:
^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit
when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is
on baftery potential when relay is off).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component Information >
Diagrams > Page 5562
Control Module: Service and Repair
AUTOMATIC FOUR WHEEL DRIVE (A4WD)
Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives
Throttle Position Information From the PCM Only.
Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage may result.
Depower the supplemental restraint system (SRS).
2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact
Disc
3. Remove the center instrument panel finish panel.
1. Remove the screws. 2. Remove the center instrument panel finish panel.
^ Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the
GEM/CTM.
1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy.
2. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions
Four Wheel Drive Selector Relay: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5568
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5569
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5570
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5571
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5572
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5573
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5574
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5575
Four Wheel Drive Selector Relay: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5576
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5577
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5578
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5579
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5580
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5581
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules - Transmission
and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 5582
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5591
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5592
Digital Transmission Range Sensor: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5593
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5594
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 5595
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications > Page 5599
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5602
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5603
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5604
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5605
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5606
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5607
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5608
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5609
Transmission Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5610
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5611
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5612
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5613
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5614
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5615
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5616
Transmission Speed Sensor: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 5617
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 5618
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 5621
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 5622
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 5623
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5629
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5630
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5631
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5632
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5633
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5634
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5635
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5636
Transmission Temperature Sensor/Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5637
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5638
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5639
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5640
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5641
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5642
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5643
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Page 5644
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Specifications > Page 5649
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > 4R70W Transmission
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > 4R70W Transmission > Page 5652
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Page 5653
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 5656
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 5657
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 5658
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions
Four Wheel Drive Selector Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5665
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5666
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5667
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5668
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5669
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5670
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5671
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5672
Four Wheel Drive Selector Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5673
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5674
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5675
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5676
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5677
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 5678
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Page 5679
Four Wheel Drive Selector Switch: Description and Operation
Switch, Push Button 4x4 Mode
The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select
the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the
instrument cluster push button, will illuminate only when the 4x4 Low position is engaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Page 5680
Four Wheel Drive Selector Switch: Service and Repair
Removal and Installation
1. Remove and reposition the center instrument panel finish panel.
2. Disconnect the 4x4 mode switch electrical connector.
3. Remove the 4x4 mode switch.
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures
PROM - Programmable Read Only Memory: Technical Service Bulletins Engine Controls - General
PCM Programming Procedures
TSB 04-24-14
12/13/04
FORD: 1997 Thunderbird 1997-2000 Contour 1997-2002 Escort 1997-2005 Crown Victoria,
Mustang, Taurus 2000-2003 Escort ZX2 2000-2005 Focus 2002-2005 Thunderbird 2005 Five
Hundred, Freestyle 1997 Aerostar 1997-2003 Windstar 1997-2005 E-Series, Expedition, Explorer,
F-150, F-250, F-Super Duty, Ranger 2000-2005 Explorer USPS 2001-2003 Explorer Sport
2001-2005 Escape, Explorer Sport Trac 2004-2005 Freestar 1997-1999 F and B Series
LINCOLN: 1997-1998 Mark VIII 1997-2002 Continental 1997-2005 Town Car 2000-2005 LS
1997-2005 Navigator 2003-2005 Aviator
MERCURY: 1997-1999 Tracer 1997-2000 Mystique 1997-2002 Cougar 1997-2005 Grand Marquis,
Sable 2005 Montego 1997-2002 Villager 1997-2005 Mountaineer 2004-2005 Monterey
This article supersedes TSB 04-21-07 to update the service procedure and to clarify this TSB
applies to all powertrain control module (PCM) reprogramming, with or without PCM replacement.
ISSUE PCMs may need to be reprogrammed or replaced as part of a repair. Additional vehicle
concerns may be caused if proper programming procedures are not followed.
ACTION Use the following procedure to reprogram PCMs.
Verify repair after reprogramming.
SERVICE PROCEDURE
PRELIMINARY STEPS - Existing PCM
Reprogramming Or PCM Replacement
1. Connect a battery charger to vehicle.
2. Use WDS if available.
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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 5685
a. Make sure WDS is docked or attached to vehicle battery supply.
b. Verify WDS software is at the latest release level.
3. If there is a communication error, attempt to communicate with a different diagnostic scan tool,
such as NGS, NGS+, VCM or another WDS.
NOTE
IF COMMUNICATION STILL CANNOT BE ESTABLISHED, VOLTAGE DROP PCM POWERS,
GROUNDS, AND CHECK VREF.
PCM REPLACEMENT - STANDARD
1. Open WDS vehicle session with original PCM installed in vehicle. If the original PCM is not able
to communicate, to open a session, proceed to the Blank Path Programming procedure.
2. Install the new PCM.
NOTE
IF WDS NEEDS TO BE USED ON A DIFFERENT VEHICLE WHILE THE NEW PCM IS BEING
INSTALLED, PLACE THE VEHICLE SESSION ON "HOLD" FOR USE LATER.
3. Attempt to start the vehicle.
4. Run KOEO Self Test to check for diagnostic trouble codes (DTCs) in PCM.
5. Check for DTC P0602/P0605/P1639.
a. If DTC P0602/P0605/P1639 is present then Programmable Module Installation (PMI) procedure
must be performed. Use the WDS session opened at Step 1.
b. If DTC P0602/P0605/P1639 is not present, then verify Programmable Parameters are properly
set such as tire size, axle ratio, etc.
6. Check for DTC B2900.
a. If DTC B2900 is present, perform PMI on the ABS module. Do Not replace ABS module for this
procedure when directed. You may be prompted to enter the 9 lines of PCM As-Built data during
this procedure.
b. If DTC B2900 is not present proceed to Step 7.
7. Diagnose all other DTCs following normal diagnostic procedures.
REPROGRAMMING DOES NOT COMPLETE OR FAILS - Existing PCM Reprogramming Or PCM
Replacement
1. Verify all cables are properly connected.
2. Verify vehicle battery is at proper charge level.
3. Verify scan tool battery is at proper charge level.
4. Attempt reprogramming procedure again.
5. If reprogramming still does not complete properly, save current session, reboot WDS, open
previous session, and attempt reprogramming again.
6. If reprogramming still does not complete or you are now unable to communicate with PCM,
proceed to the Blank Path Programming procedure.
BLANK PATH PROGRAMMING - Existing PCM Reprogramming Or PCM Replacement
Perform this procedure prior to PCM replacement if a vehicle comes in with a PCM that will not
communicate, or if steps earlier in this TSB directed you to this procedure.
1. Verify powers and grounds to PCM by loading and voltage drop testing circuits.
2. Follow Pin Point Tests to verify network integrity.
NOTE
IGNITION MUST REMAIN IN THE OFF POSITION UNTIL PERFORMING STEP 8. DO NOT
TURN THE KEY ON WHEN WDS IS
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Ford Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Engine Controls - General PCM Programming Procedures > Page 5686
INITIALLY CONNECTED TO THE DLC.
3. Connect WDS to vehicle.
4. Select "16 pin", select "All others, except those below", press TICK.
5. Screen shows installation of cable, press TICK.
6. Screen shows to turn ignition ON. DO NOT TURN IGNITION ON. Press TICK.
7. Screen shows progress bar, then screen tells you "No communication can be established with
the PCM" and asks you if you want to retry? Select "NO". With the ignition key still OFF, press
TICK.
8. Screen shows to turn ignition ON. Turn ignition on, press TICK.
9. Screen shows "The PCM installed to this vehicle is blank". You will be prompted to select VIN
from a list of previous sessions. Press TICK.
10. When previous sessions are shown select "None of the above".
11. Screen shows 'To enable WDS to reprogram the PCM with the correct calibration", enter one of
the following: Vehicle Calibration # (7 digits), Tear Tag # (4 digits), or PCM part #, press TICK.
12. Highlight the box next to the selection chosen, and enter ONLY ONE of the selections listed
above. Press TICK.
13. Follow and answer correctly all remaining screens.
14. Once PCM is reprogrammed communication should be reestablished and PATS system can be
reset (if necessary) as per Section 419-01 of the Workshop Manual.
WARRANTY STATUS: Information Only
Disclaimer
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5693
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5694
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5695
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5698
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5699
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5700
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5701
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5702
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5703
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5704
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5705
Pressure Regulating Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5706
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5707
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5708
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5709
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5710
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5711
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5712
Diagram 29-4
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5713
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
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Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5714
Pressure Regulating Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5715
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5716
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5717
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications
Shift Interlock Solenoid: Specifications
Shift Lock Actuator Bolts 62.5-98 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Specifications > Page 5721
Shift Interlock Solenoid: Service and Repair
Removal
1. Remove the steering column assembly.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced.
Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
Shift Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5725
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5726
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5727
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Shift Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5730
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5731
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5732
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5733
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5734
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5735
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5736
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5737
Shift Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5738
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5739
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5740
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5741
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5742
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5743
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 5744
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5745
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5746
Shift Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5747
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5748
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5749
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page
5753
Torque Converter Clutch Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page
5754
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page
5755
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page
5756
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5759
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5760
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Information and Instructions > Page 5761
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5762
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Information and Instructions > Page 5763
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Information and Instructions > Page 5766
Torque Converter Clutch Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Information and Instructions > Page 5768
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Information and Instructions > Page 5769
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Information and Instructions > Page 5770
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5771
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5772
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Information and Instructions > Page 5773
Diagram 29-4
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5774
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5775
Torque Converter Clutch Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5776
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5777
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
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Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5778
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Specifications
Transfer Case Actuator: Specifications
Transfer case shift motor bolts
..............................................................................................................................................................
10 Nm (89 inch lbs.)
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Information and Instructions
Transfer Case Actuator: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Information and Instructions > Page 5785
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Information and Instructions > Page 5786
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
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Information and Instructions > Page 5787
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Information and Instructions > Page 5788
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Information and Instructions > Page 5789
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Information and Instructions > Page 5792
Transfer Case Actuator: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram
Information and Instructions > Page 5795
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram
Information and Instructions > Page 5796
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram
Information and Instructions > Page 5797
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram
Information and Instructions > Page 5798
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Diagram
Information and Instructions > Page 5799
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5800
Transfer Case Actuator: Service and Repair
Removal and Installation
1. With the vehicle in the NEUTRAL position, raise and support the vehicle.
2. Remove the heat shield.
3. Disconnect the electrical connector.
4. Remove the coil wire from the electrical connector.
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Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5801
1. Remove the connector interlock. 2. Remove the coil wire pin.
- Use the proper electrical connector pin remover.
5. Remove the rear output shaft speed sensor.
- Carefully remove the sensor from the transfer case.
6. Remove the four bolts and the transfer case shift motor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information > Diagrams > Page 5802
7. Remove the front output shaft speed sensor.
- Carefully remove the sensor from transfer case.
8. NOTE: Make sure the motor mounting surfaces are clean.
Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case.
9. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5809
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5810
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Page 5813
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Page 5814
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5815
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Page 5816
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Page 5817
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Page 5818
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Page 5819
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Page 5820
Pressure Regulating Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Page 5821
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Page 5822
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5823
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5824
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Page 5825
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Page 5826
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions >
Page 5827
Diagram 29-4
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Pressure Regulating Solenoid, A/T > Component Information > Diagrams > Page 5828
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
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Pressure Regulating Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
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2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Interlock Solenoid > Component Information > Specifications
Shift Interlock Solenoid: Specifications
Shift Lock Actuator Bolts 62.5-98 in.lb
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Shift Interlock Solenoid: Service and Repair
Removal
1. Remove the steering column assembly.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced.
Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations
Shift Solenoid: Locations
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 5842
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5845
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5847
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5848
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5849
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5850
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5851
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5852
Shift Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5853
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5854
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5855
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5856
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5858
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 5859
Diagram 29-4
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5860
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5861
Shift Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Diagrams > Page 5862
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
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2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5868
Torque Converter Clutch Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5869
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Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Specifications > Page 5871
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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> Page 5874
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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> Page 5875
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5876
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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> Page 5877
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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> Page 5878
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> Page 5879
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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> Page 5880
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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> Page 5881
Torque Converter Clutch Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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> Page 5882
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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> Page 5883
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5884
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5885
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5886
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5887
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
> Page 5888
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5889
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5890
Torque Converter Clutch Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5891
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5892
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Diagrams > Page 5893
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment
Band Apply Servo: Adjustments Front Band Adjustment
Special Tools
1. Disconnect the battery ground cable. 2. Raise the vehicle on a hoist.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. CAUTION: Do not allow front band adjustment screw to back out. Band strut could fall out of
position.
CAUTION: Throw the locknut away. The locknut is not reusable for assembly.
Remove and discard the locknut.
5. CAUTION: Install, but do not tighten, a new locknut on the band adjustment screw. Apply
petroleum jelly to the locknut seal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment > Page 5898
CAUTION: The servo must be installed prior to band adjustment.
Note: The wrench will click at the specified torque. Install new locknut, do not tighten at this time.
Tighten front band adjustment screw using the Band Adjuster Wrench Kit and back off front band
adjustment screw exactly two (2) turns and hold that position.
6. Tighten the front band locknut.
1. Hold the front band adjustment screw stationary. 2. Tighten the front band locknut.
7. Install the shift cable.
1. Install the shift cable. 2. Install the shift cable to the manual control lever.
8. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment > Page 5899
Band Apply Servo: Adjustments Intermediate Band Adjustment
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Remove the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the
bracket.
4. Remove the digital transmission range (TR) sensor.
5. CAUTION: Do not allow the screw to back out. Band strut could fall out of position.
CAUTION: Throw the locknut away. The locknut is not reusable for assembly.
Remove and discard the locknut.
6. CAUTION: Install, but do not tighten, a new locknut on the screw. Apply petroleum jelly to the
locknut seal.
CAUTION: The intermediate servo must be installed prior to band adjustment.
Note: The wrench will click at the specified torque. Install new locknut, do not tighten at this time.
Tighten the screw using the Band Adjuster Wrench Kit and back off the screw exactly two (2) turns
and hold that position.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment > Page 5900
7. Tighten the intermediate band locknut.
1. Hold the screw stationary. 2. Tighten the intermediate band locknut.
8. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
9. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must be in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
10. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Adjustments > Front Band Adjustment > Page 5901
11. Connect the digital transmission range (TR) sensor electrical connector.
12. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
13. Verify that the shift cable is adjusted. 14. Lower the vehicle. 15. Connect the battery ground
cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo
Band Apply Servo: Service and Repair Front Servo
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support vehicle.
3. Remove the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the
bracket.
4. Remove the digital transmission range (TR) sensor. 5. Remove the main control valve body. 6.
Remove the three way catalytic converter (TWC).
7. Remove the transmission servo heat shield.
1. Remove the transmission servo heat shield nut. 2. Remove the transmission servo heat shield.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5904
8. Remove the front band locknut and unscrew the front band adjusting screw.
- Discard the front band locknut after removal.
9. CAUTION: Servo cover is under spring pressure.
Using Servo Cover Compressor, remove the front band servo cover retaining ring. 1. Install the
Servo Cover Compressor and compress the front band servo cover. 2. Remove the front servo
cover retaining ring.
- Slowly remove tension on the J-hook nut and remove the servo cover compressor.
10. CAUTION: Servo removal tool should be used to prevent damage to servo and bore.
Use Servo Removal Tool to remove the front band servo cover, servo piston and servo piston
spring. Insert Servo Removal Tool into the transmission case, locate on servo rod, and remove front band
servo cover, servo piston and servo piston spring.
Installation
1. Assemble the front band servo cover, front band servo piston, and the servo piston spring.
1. Install the front band servo piston into the front band servo cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5905
2. Install the servo piston spring on the front band servo piston.
2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past
relief hole in case, or O-ring damage may occur.
Install the front band servo assembly into the transmission case. Lubricate the front band servo cover O-ring with petroleum jelly.
3. Use Servo Cover Compressor to install the front band servo cover retaining ring.
1. Install the Servo Cover Compressor and compress the front band servo cover. 2. Install the front
servo cover retaining ring.
4. Install the main control valve body. 5. Adjust the front band.
6. Position the transmission servo heat shield on the transmission and install the nut. 7. Install the
three way catalytic converter.
8. Install the shift cable.
1. Install the shift cable. 2. Install the shift cable to the manual control lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5906
9. Install the digital transmission range (TR) sensor.
10. Lower the vehicle. 11. Connect the battery ground cable. 12. Fill the transmission to the proper
fluid level and check for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5907
Band Apply Servo: Service and Repair Intermediate Servo
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Remove the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Remove the shift cable from the
bracket.
4. Remove the digital transmission range (TR) sensor. 5. Remove the three way catalytic converter
(TWC). 6. Remove the main control valve body.
7. Remove the transmission servo heat shield.
1. Remove the transmission servo heat shield nut. 2. Remove the transmission servo heat shield.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5908
8. Remove the intermediate band locknut and unscrew the screw.
- Discard the intermediate band locknut after removal.
9. CAUTION: Servo cover is under spring tension. Use caution when removing.
Using Servo Cover Compressor, remove the intermediate band servo cover retaining ring. 1. Install
the Servo Cover Compressor and compress the intermediate band servo cover. 2. Remove the
intermediate servo cover retaining ring.
- Slowly remove tension on the J hook nut and remove the servo cover compressor.
10. CAUTION: Servo removal tool should be used to prevent damage to the servo, servo cover,
and bore.
Use Servo Removal Tool to remove the intermediate band servo cover, intermediate band servo
piston and servo piston spring. Insert Servo Removal Tool into the transmission case, and remove servo cover, intermediate band
servo piston and servo piston spring.
Installation
1. Assemble the intermediate band servo cover, intermediate band servo piston, and the servo
piston spring.
1. Install the intermediate band servo piston into the intermediate band servo cover. 2. Install the
servo piston spring on the intermediate band servo piston.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5909
2. CAUTION: Do not damage O-ring during installation. Do not press servo cover and O-ring past
relief hole in case, or O-ring damage may occur.
Install the intermediate band servo piston assembly into the transmission case. Lubricate intermediate band servo cover O-ring with petroleum jelly.
3. Using Servo Cover Compressor, install the intermediate band servo cover retaining ring.
1. Install the Servo Cover Compressor and compress the intermediate band servo cover. 2. Install
the intermediate servo cover retaining ring.
4. Adjust the intermediate band. 5. Install the main control valve body. 6. Install the digital
transmission range (TR) sensor.
7. Position the transmission servo heat shield on the transmission and install the nut.
8. Install the shift cable.
1. Install the shift cable. 2. Install the shift cable to the manual control lever.
9. Install the three way catalytic converter.
10. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5910
11. Connect the battery ground cable. 12. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON (R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R)
V specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5911
Band Apply Servo: Service and Repair Low/Reverse Servo Assembly
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Remove the
transmission pan.
4. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
5. Remove the low/reverse band servo cover.
1. Remove the low/reverse band servo cover screws. 2. Remove the low/reverse band servo cover
and gasket. Discard the low/reverse servo separator plate cover gasket.
6. Remove the low/reverse band servo piston and rod assembly.
Installation
1. Clean and inspect the low/reverse band servo piston bore and the low/reverse band servo piston
and rod.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5912
2. Install the low/reverse band servo piston and rod.
1. Install the low/reverse band servo piston and rod assembly. 2. Install a new low/reverse band
servo separator plate cover gasket. 3. Install the low/reverse band servo cover.
- Loosely install the low/reverse band servo piston cover screws.
3. Tighten the servo cover screws in the sequence shown.
4. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
5. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T >
Component Information > Service and Repair > Front Servo > Page 5913
6. Tighten the transmission fluid pan bolts.
- Use a crisscross sequence to tighten the transmission fluid pan screws.
7. Lower the vehicle. 8. Connect the battery ground cable. 9. Fill the transmission to the proper fluid
level and check for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair
Control Module: Service and Repair
Removal
1. Remove the transmission control switch (TCS).
1. Remove the TCS cover. 2. Remove the TCS.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Specifications
Extension Housing: Specifications
Extension housing screws and studs 27 - 39 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Service and Repair > Extension Housing Gasket - 4X2
Extension Housing: Service and Repair Extension Housing Gasket - 4X2
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original alignment.
Mark the rear driveshaft.
4. Remove the rear driveshaft.
1. Remove the bolts. 2. Remove the rear driveshaft.
5. Remove the nuts.
6. Raise and support the transmission.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5922
7. Remove the transmission mount.
1. Remove the screws. 2. Remove the transmission mount.
8. Remove the extension housing screws and studs.
9. CAUTION: The parking pawl, parking pawl return spring and parking pawl shaft could fall out
during removal of the extension housing.
Remove the extension housing. Discard the extension housing gasket.
Installation
1. Clean the extension housing and install new extension housing gasket. Make sure that the
parking pawl, spring, and shaft are correctly installed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5923
2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup.
Install the extension housing. 1. Position the extension housing. 2. Install the extension housing
screws. 3. Install the extension housing studs.
3. Install the transmission mount.
1. Position the transmission mount on the extension housing. 2. Install the transmission
mount-to-extension housing screws.
4. Install the transmission mount into the crossmember and tighten the transmission mount nuts.
5. Note: Align the driveshaft with the marks made during removal to ensure correct balance.
Align and install the rear driveshaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5924
6. Install the bolts. 7. Lower the vehicle. 8. Connect the battery ground cable. 9. Fill the
transmission to the proper fluid level and check for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5925
Extension Housing: Service and Repair Extension Housing Gasket - 4X4
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original alignment.
Mark the rear driveshaft.
4. Remove the transfer case. 5. Remove the wire harness locators from the extension housing wire
bracket.
6. Remove the transmission mount nuts.
7. Raise and support the transmission.
8. Remove the transmission mount.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5926
1. Remove the transmission mount-to-extension housing screws. 2. Remove the transmission
mount.
9. Remove the six extension housing screws and studs.
10. Note: The parking pawl, parking pawl return spring and parking pawl shaft may fall out during
removal of the extension housing.
Remove the extension housing. Discard the extension housing gasket.
Installation
1. Clean the extension housing and install a new extension housing gasket. Make sure that the
parking pawl, spring, and shaft are correctly installed.
2. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup.
Install the extension housing. Position the extension housing and install the six extension housing screws and studs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Service and Repair > Extension Housing Gasket - 4X2 > Page 5927
3. Install the transmission mount.
1. Position the transmission mount on the extension housing. 2. Install the screws.
4. Install the transmission mount into the crossmember and tighten the nuts. 5. Install the wire
harness locators from the extension housing wire bracket. 6. Install the transfer case.
7. Note: Align the driveshaft with the marks made during removal to ensure correct balance.
Align and install the rear driveshaft.
8. Install the bolts. 9. Connect the battery ground cable.
10. Fill the transmission to proper fluid level and check for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid ..............................................................................................................................
..................................................................... 10.3 qts Note: Approximately Dry Fill Capacity
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 5932
Fluid - A/T: Fluid Type Specifications
Transmission Fluid Type
Type .....................................................................................................................................................
............................................................. MERCON V
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Pan, Gasket and Filter
Fluid - A/T: Service and Repair Fluid Pan, Gasket and Filter
Fluid Pan, Gasket and Filter
Removal
1. Raise and support the vehicle.
NOTE: If equipped, the transmission servo heat shield needs to be unclipped from the fluid pan rail
and positioned out of the way for fluid pan removal.
If equipped, loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
- Disconnect the LH three-way catalytic converter heated oxygen sensor connectors and remove
the converter.
- Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow fluid to
drain. After fluid is drained, remove the front two transmission fluid pan screws.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5935
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V Automatic Transmission Fluid
XT-5-QM meeting Ford specification MERCON
(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter.
^
Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5936
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
^ Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
^ Use a crisscross sequence to tighten the transmission fluid pan screws.
6. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the
vehicle.
8. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
Fill transmission to the correct fluid level and check for correct transmission operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5937
^ Use MERCON(R) V Automatic Transmission Fluid XT-5-QM meeting Ford specification
MERCON(R) V.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5938
Fluid - A/T: Service and Repair Drain and Refill W/Automated Equipment
Transmission Fluid Drain and Refill-Automated Equipment
Special Tool(s)
Draining
CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission
fluid additives, treatments or cleaning agents. The use of these materials can affect the operation
of the transmission, resulting in internal component failure.
CAUTION: Always refer to the instructions supplied with the flush and fill machine.
NOTE: This is a new procedure for draining and adding transmission fluid using a suitable
transmission flush and fill machine. 1. With the vehicle in PARK, position on a hoist. 2. Use a
suitable flush and fill machine to change the fluid. 3. When connecting the flush and fill machine,
connect the machine to the fluid cooler tube after the fluid cooler on the cooler return tube. This will
help remove any foreign material trapped in the fluid coolers.
4. Carry out the fluid exchange process.
Refill
1. Use only clean automatic transmission fluid. 2. Once the fluid exchange has been completed,
disconnect the flush and fill machine. Reconnect any disconnected fluid cooler tubes. 3. Lower the
vehicle. 4. With the engine running and the transmission at normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission fluid level
and check for any leaks. If fluid is needed, add fluid in increments of 0.24 liter (0.5 pint) until the
correct level is achieved (fluid should be in the cross-hatched area of the fluid level indicator).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5939
Fluid - A/T: Service and Repair Vehicles Not Equipped With Torque Converter Drain Plug
Transmission Fluid Drain and Refill- Vehicles Not Equipped With Torque Converter Drain Plug
Draining
CAUTION: Use only clean automatic transmission fluid. Do not use any supplemental transmission
fluid additives, treatments or cleaning agents. The use of these materials can affect the operation
of the transmission, resulting in internal component failure.
1. With the vehicle in PARK, position on a hoist.
2. NOTE: If equipped, the transmission servo heat shield must be unclipped from the fluid pan rail
and positioned aside for fluid pan removal.
If equipped, loosen the nut and position the heat shield aside.
3. Place a drain pan under the transmission fluid pan.
4. Drain the transmission fluid.
^ Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan screws. Pry the rear of the transmission fluid pan down and allow the fluid to
drain. After the fluid is drained, remove the front two transmission fluid pan screws.
5. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5940
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces.
Refill
1. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan
^ Loosely install the transmission fluid pan screws.
2. Tighten the transmission fluid pan screws.
^ Tighten the transmission fluid pan screws in a crisscross sequence.
3. If equipped, position the servo heat shield over the servos and clip it to the pan rail. 4. Lower the
vehicle.
5. NOTE: When filling a dry transmission and converter, start with a minimum of 3.7 liters (4
quarts).
With the engine running and the transmission at normal operating temperature 66-77°C
(150-170°F), check and adjust the transmission fluid level and check for any leaks. If fluid is
needed, add fluid in increments of 0.24 liter (0.5 pint) until the correct level is achieved (fluid should
be in the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Pan, Gasket and Filter > Page 5941
cross-hatched area of the fluid level indicator).
6. Apply the park brake, and start the engine. 7. Move the range selector lever through all the
gears. 8. Check the transmission fluid level.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications
Fluid Filter - A/T: Specifications
Transmission fluid filter screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5945
Fluid Filter - A/T: Service and Repair
Removal
1. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
- Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan bolts. Pry the rear of the transmission fluid pan down and allow fluid to drain.
After fluid is drained remove the front two transmission fluid pan bolts.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5946
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V; Automatic Transmission Fluid
XT-5-QM meeting Ford specification
MERCON(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5947
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
- Use a crisscross sequence to tighten the transmission fluid pan screws.
6. Position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle.
8. Note: When filling a dry transmission and converter start with a minimum of 3.7 liters (4 quarts).
Fill transmission to the proper fluid level and check for proper transmission operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Specifications > Page 5948
- Use MERCON V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON
V.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications
Fluid Line/Hose: Specifications
Transmission cooler lines to case connectors 26 - 32 ft.lb
Transmission cooler line nut 18 - 23 ft.lb
Transmission Auxiliary Fluid Cooler Hose Clamps 27 - 35 in.lb
Transmission Fluid Cooler Tube Fitting To Radiator 10 - 16 ft.lb
Transmission Fluid Cooler Tube to Case Fitting 18 - 23 ft.lb
Transmission Cooler Lines Bracket Bolts 28 - 38 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 5952
Fluid Line/Hose: Service and Repair
Removal
1. WARNING: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so may result in unexpected inflation or deflation of the air springs,
which may result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Remove the radiator air deflector.
1. Remove the bolts. 2. Remove the radiator air deflector.
3. Remove the nut, bolt and transmission cooler line bucket.
4. Remove the transmission fluid cooler tubes.
1. Remove the clips. 2. Disconnect the fittings.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 5953
- Use a backup wrench to hold the case fitting secure.
3. Remove the nut. 4. Remove the transmission fluid cooler tubes.
Installation
1. Note: When a transmission fluid cooler tube is replaced, each replacement tube must be
fabricated from the same size tube as the original.
Shape a new transmission fluid cooler tube. Use the prior tube as a guide.
- Install the appropriate fittings.
2. CAUTION: To prevent damage, make sure all plugs are removed from port openings before
installing tubes.
CAUTION: To prevent cross threading, all tube nuts must be hand started before being torqued to
specification.
Install the transmission fluid cooler tubes. 1. Install the clips. 2. Connect the tube fittings to the
radiator. 3. Connect the tube fittings to the transmission.
- Use a backup wrench to hold the case fitting secure.
4. Install the tube bracket nut. 5. Install the transmission fluid cooler tubes.
3. Install the nut, bolt, and transmission cooler line bracket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Specifications > Page 5954
4. Install the radiator air deflector.
- Install the bolts.
5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Lower the vehicle.
6. Fill transmission fluid to the proper level using the correct fluid and inspect for leaks.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility
Fluid Pan: Technical Service Bulletins A/T - 5R44E/5R55E Part Level Change/Compatibility
TSB 06-24-13
11/20/06
5R44E / 5R55E SERVICE PART LEVEL CHANGE / COMPATIBILITY
FORD: 1997 Aerostar 1997-2001 Explorer 1997-2007 Ranger 2001-2003 Explorer Sport
2001-2005 Explorer Sport Trac
MERCURY: 1998-2001 Mountaineer
ISSUE Some vehicles equipped with a 5R44E or 5R55E automatic transmission may require repair
of the transmission. This TSB is being published as informational only in order to avoid mix I match
of incorrect service parts which will cause a fluid leak. Beginning with 8/29/2006 production, the
5R44E or 5R55E automatic transmission will have a new transmission case, fluid pan, a
REUSABLE fluid pan gasket and new fluid pan screws.
ACTION Follow the Service Tips.
SERVICE TIPS
NOTE
DO NOT MIX AND MATCH PARTS OR LEAKAGE WILL OCCUR.
NOTE
THE NEW PAN GASKET IS NOT INCLUDED IN THE GASKET AND SEAL KIT. IT CAN ONLY BE
ORDERED SEPARATELY.
The 5R44E / 5R55E transmission pan gasket has been redesigned to be reusable if it is removed
for a non-leak related transmission service concern. The gasket should be inspected for damage
and cleaned, along with the mating surfaces, before reuse. The case and fluid pan rails have been
redesigned to properly mate with the new gasket to eliminate fluid leaks. The new case, pan, and
gasket maybe used to service past model transmissions from 1997.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5959
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5960
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5961
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > A/T - 5R44E/5R55E Part Level Change/Compatibility > Page 5962
For 1997-2007 (early production) 4R44E I 5R44E and 5R55E when servicing the fluid pan gasket
(7A191), the fluid pan (7A194) or the case (7005) do not mix and match old level and new level
parts. The old level gasket, refer to Figure 3 (7A191) will be continued for past model applications.
If replacing the older design level case, refer to Figure 1 (7005) and/or old lever fluid pan, refer to
Figure 2 (7A194), ALL new components must be used. This includes the case (7005), refer to
Figure 4, fluid pan (7A194), refer to Figure 5, fluid pan gasket (7A191), refer to Figure 6 and pan
screws (W500212) (new torque specification - 7 lb-ft (10 N.m) refer to Figure 7.
For correct part numbers refer to your parts catalogue.
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > Page 5963
Fluid Pan: Specifications
Pan Bolt Torque ...................................................................................................................................
...........................................................115-135 in. lbs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > Page 5964
Fluid Pan: Service and Repair
Removal
1. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
2. Place a drain pan under the transmission fluid pan.
3. Drain transmission fluid.
- Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan bolts. Pry the rear of the transmission fluid pan down and allow fluid to drain.
After fluid is drained remove the front two transmission fluid pan bolts.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > Page 5965
5. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
6. Clean and inspect the transmission fluid pan and magnet. Clean all mating surfaces. 7. Flush the
transmission fluid cooler and transmission fluid cooler lines.
Installation
1. CAUTION: Lubricate fluid filter O-rings with MERCON(R) V; Automatic Transmission Fluid
XT-5-QM meeting Ford specification
MERCON(R) V or they may be damaged.
Lube and install new O-rings onto the transmission fluid filter. Install a new transmission fluid filter. Position transmission fluid filter on the main control valve body.
2. CAUTION: Make sure wire harness is not pinched under filter.
Install transmission fluid filter screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > Page 5966
3. Position the oil pan magnet in the transmission fluid pan.
4. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
5. Tighten the transmission fluid pan screws.
- Use a crisscross sequence to tighten the transmission fluid pan screws.
6. Position the servo heat shield over the servos and clip it to the pan rail. 7. Lower the vehicle.
8. Note: When filling a dry transmission and converter start with a minimum of 3.7 liters (4 quarts).
Fill transmission to the proper fluid level and check for proper transmission operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component
Information > Technical Service Bulletins > Page 5967
- Use MERCON V; Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON
V.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Specifications
Fluid Pump: Specifications
Fluid pump screws 16 - 21 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Overdrive Indicator Lamp > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Overdrive Indicator Lamp > Component Information > Locations > Page 5975
Overdrive Indicator Lamp: Description and Operation
Overdrive (O/D) Off
The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function
indicator will also flash off and on if a transmission
malfunction is detected.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Shift Indicator > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Shift Indicator > Component Information > Locations > Page 5979
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D)
position.
- Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents
counterclockwise (D) position).
3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever.
4. Center the pointer in the middle of the (D) position.
- Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and
compare with the transmission settings.
- Readjust if necessary.
7. Install the upper instrument panel steering column cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T
> Transmission Mode Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Overdrive Indicator Lamp >
Component Information > Locations > Page 5986
Overdrive Indicator Lamp: Description and Operation
Overdrive (O/D) Off
The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function
indicator will also flash off and on if a transmission
malfunction is detected.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair
Parking Pawl: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Remove the transmission fluid pan.
1. Remove the transmission fluid pan. 2. Remove and discard the transmission fluid pan gasket.
5. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5990
6. Remove wire loom guide and protector.
- Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
7. Disconnect the solenoid electrical connectors.
1. Disconnect shift solenoids SSB and SSD electrical connectors. 2. Disconnect the torque
converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control
(EPC) solenoid electrical connector.
8. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
Remove the EPC, SSB, and SSD solenoids. 1. Remove the wire harness. 2. Remove the solenoid
clamp screws. 3. Remove the solenoid clamp. 4. Remove the EPC, SSB, and SSD solenoids.
9. CAUTION: Do not pry on the other wires or damage to the connector case surface may result.
Disconnect the turbine shaft speed (TSS) sensor electrical connector from the transmission case
(16 pin) electrical connector. 1. Disconnect the TSS sensor electrical connector. 2. Remove the
TSS sensor wire locator.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5991
10. CAUTION: Do not overstretch the retaining spring.
Remove the transmission case (16 pin) electrical connector retaining spring.
11. CAUTION: Do not damage the connector or harness.
Remove the transmission case (16 pin) electrical connector. Compress the tabs on the connector.
- Push the connector out of the transmission case.
12. Remove the manual control valve detent lever spring.
1. Remove the screw. 2. Remove the spring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5992
13. CAUTION: To avoid damage, make sure the wrench does not strike the manual valve inner
lever pin.
Remove the manual valve inner lever nut.
14. Remove the manual valve inner lever and parking lever actuating rod.
15. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original alignment.
Mark the rear driveshaft.
16. Remove the rear driveshaft.
1. Remove the bolts. 2. Remove the rear driveshaft.
17. If equipped, remove the transfer case.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5993
18. Note: If damage is found to the parking gear, the transmission must be removed and
disassembled.
Note: The parking pawl, parking pawl return spring and parking pawl shaft may fall out during
removal of the extension housing.
Remove the extension housing and discard the extension housing gasket.
19. Inspect the parking pawl, parking pawl return spring and the parking pawl shaft.
- Replace if required.
Installation
1. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup. Verify that the output shaft is
locked in the PARK position.
Align the flats of the manual valve inner lever with the flats on the manual control lever shaft. Install
the manual valve inner lever and parking lever actuating rod onto the manual control lever shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5994
2. CAUTION: Do not bend the manual valve inner lever pin.
Install the manual valve inner lever nut.
3. Install the manual valve detent spring.
4. Clean the extension housing and install a new extension housing gasket. Make sure that the
parking pawl, spring, and shaft is correctly installed.
5. CAUTION: Make sure the parking lever actuating rod is correctly seated into the case parking
rod guide cup.
Install the extension housing. 1. Position the extension housing, 2. Install the extension housing
screws. 3. Install the extension housing stud.
6. If equipped, install the transfer case.
7. Note: Align the drive shaft with the marks made during removal to ensure correct balance.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5995
Install the rear driveshaft bolts.
8. Note: Make sure the tab is in the lock position.
Note: Install new O-rings on the transmission case (16 pin) electrical connector.
Install the transmission case (16 pin) electrical connector. Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly.
9. Press the transmission case (16 pin) electrical connector through the case until a click is heard.
10. CAUTION: Align the slot on the TSS sensor electrical connector with the slot in the 16 pin case
connector.
Install the TSS sensor wire. 1. Install the TSS sensor wire into (16 pin) electrical connector. 2.
Install the TSS sensor wire into locator.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5996
11. CAUTION: Do not overstretch the retaining spring.
Install the transmission case (16 pin) electrical connector retaining spring.
12. Install the EPC, SSD, and SSB solenoids.
13. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5997
14. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors.
15. CAUTION: Excessive pressure may break the retaining pins.
Install the wire loom guide and protector. Align the retaining pins to the holes in the solenoid clamps and gently press in the wire loom guide
and protector.
16. Install the transmission fluid pan.
1. Install a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align the
transmission fluid pan.
- Loosely install the transmission fluid pan screws.
17. Using a crisscross sequence, tighten the transmission fluid pan screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T >
Component Information > Service and Repair > Page 5998
18. Position the servo heat shield over the servos and clip it to the pan rail. 19. Lower the vehicle.
20. Connect the battery ground cable. 21. Fill transmission to proper fluid level and check for
proper transmission operation.
- Use MERCON(R) V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Page 6002
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Page 6003
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Locations > Page 6004
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6007
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6008
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6009
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6010
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6011
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6012
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6013
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6014
Pressure Regulating Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6015
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6016
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6017
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6018
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6019
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6020
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6021
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 6022
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 6023
Pressure Regulating Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 6024
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 6025
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating
Solenoid, A/T > Component Information > Diagrams > Page 6026
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T >
Control Module, A/T > Component Information > Service and Repair
Control Module: Service and Repair
Removal
1. Remove the transmission control switch (TCS).
1. Remove the TCS cover. 2. Remove the TCS.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T
Seals and Gaskets: Service and Repair Extension Housing Seal, A/T
Special Tools
Special Tools
Removal
1. Raise and support the vehicle.
2. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original alignment.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 6035
Mark the rear driveshaft.
3. Remove the rear driveshaft.
1. Remove the rear driveshaft bolts. 2. Remove the rear driveshaft.
4. Using the Converter Oil Seal Remover and Impact Slide Hammer, remove the extension housing
seal.
5. CAUTION: Use the extension housing bushing remover carefully so that the seal area is not
damaged.
Remove extension housing bushing. 1. Install Housing Bushing Remover. 2. Remove extension
housing bushing.
Installation
1. CAUTION: The lube hole in the extension housing bushing must be aligned with the lube groove
in the extension housing. This groove is located
at the 3 o'clock position when viewed from the rear.
Note: Inspect the counterbore of the extension housing for burrs. Remove any burrs from the
extension housing counterbore with an oil stone.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 6036
Position the extension housing bushing into the extension housing.
2. CAUTION: The tool will bottom when bushing is in the proper position.
Use the Housing Bushing Replacer to install the extension housing bushing.
3. Position new extension housing seal with drain hole in the 6 o'clock position.
4. Use the Extension Housing Seal Replacer to install the extension housing seal.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 6037
5. Note: Inspect the driveshaft slip-yoke for wear and damage. Replace if required.
Align the drive shaft with the marks made during removal to ensure correct balance.
6. Install the rear driveshaft bolts. 7. Lower the vehicle. 8. Fill the transmission to the proper fluid
level and check for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V
specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 6038
Seals and Gaskets: Service and Repair Shift Shaft Seal
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and-support vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Note: It is not necessary to remove the transmission fluid filter to perform this procedure.
Remove the transmission fluid pan.
5. Remove the digital transmission range (TR) sensor.
6. Remove the manual control valve detent lever spring.
1. Remove the manual control valve detent lever spring screw. 2. Remove the manual control valve
detent lever spring.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 6039
7. CAUTION: Do not damage the valve inner lever pin.
Remove the manual valve inner lever nut.
8. Separate the manual valve inner lever and the parking lever actuating rod.
9. CAUTION: Do not damage the case fluid pan rail.
Remove the manual control lever shaft spring pin. Tap lightly on each side of the manual control lever shaft spring pin with a drift punch.
- Pry the spring pin out of its bore.
10. Remove the manual control lever shaft.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 6040
11. CAUTION: Do not damage the bore.
Remove the manual control lever shaft seal.
Installation
1. Using the special tool, install the manual control lever shaft seal.
- Lubricate the manual control lever shaft seal with petroleum jelly.
2. Install the manual control lever shaft.
3. CAUTION: Use care not to damage the fluid pan rail surface when installing the retaining pin.
Align the manual control lever shaft alignment groove with the manual control lever shaft spring pin
bore in the transmission case. Tap the manual control lever shaft spring pin into the transmission case.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 6041
4. Align flats of the manual valve inner lever with flats on the manual control lever shaft. Install the
manual valve inner lever and parking lever
actuating rod onto the manual control lever shaft.
5. CAUTION: Do not bend the manual valve inner lever pin.
Install the manual valve inner lever nut.
6. CAUTION: Park pawl actuating rod must be properly installed into parking pawl and guide cup
located in extension housing. Verify park linkage
function.
Verify that the output shaft is locked in the PARK position.
7. Install the manual valve detent spring. 8. Install the transmission fluid pan with new pan gasket.
9. Position the servo heat shield over the servos and clip it to the pan rail.
10. Install the digital transmission range (TR) sensor. 11. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Service and Repair > Extension Housing Seal, A/T > Page 6042
12. Connect the battery ground cable. 13. Fill the transmission to proper level and check for proper
transmission operation.
- Use MERCON V at Automatic Transmission Fluid XT-5-QM meeting Ford specification MERCON
V.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 6050
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 6051
Digital Transmission Range Sensor: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 6052
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 6053
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information >
Specifications > Page 6054
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6058
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6061
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6062
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6063
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6064
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6065
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6066
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6067
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6068
Transmission Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6069
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6070
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6071
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6072
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6073
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6074
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6075
Transmission Speed Sensor: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
6076
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6077
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
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> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift >
Page 6080
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
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> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift >
Page 6081
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
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> Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift >
Page 6082
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6088
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6089
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6090
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6091
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6092
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6093
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6094
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6095
Transmission Temperature Sensor/Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6096
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6097
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6098
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6099
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6100
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6101
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6102
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches - A/T
> Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6103
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Specifications
Shift Interlock Solenoid: Specifications
Shift Lock Actuator Bolts 62.5-98 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift
Interlock Solenoid > Component Information > Specifications > Page 6108
Shift Interlock Solenoid: Service and Repair
Removal
1. Remove the steering column assembly.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced.
Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations
Shift Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > Page 6112
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > Page 6113
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > Page 6114
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6117
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6118
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6119
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6120
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6121
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6122
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6123
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6124
Shift Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6125
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6126
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6127
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6128
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6129
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6130
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Diagram Information and Instructions > Page 6131
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 6132
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 6133
Shift Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 6134
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 6135
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Diagrams > Page 6136
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component
Information > Service and Repair
Shifter A/T: Service and Repair
Removal
1. Remove the ignition switch.
2. Remove the upper steering column shroud.
3. Remove the gearshift lever.
1. Disconnect the shift control selector lever harness connector. 2. Remove and discard the
gearshift lever pin. 3. Remove the gearshift lever.
Installation
1. Note: The gearshift lever pin must be replaced whenever removed.
Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications
Shift Cable: Specifications
Shift Cable Bracket 15-21 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 6144
Shift Cable: Adjustments
1. Place the gearshift lever in the (D) position and hang a 3.6 kg (8 lb.) weight on the gearshift
lever. 2. Raise and support the vehicle.
3. Disconnect the transmission shift cable from the manual control lever.
4. Pull out the transmission shift cable adjustment lock tab on the shift cable body.
5. Place the manual control lever in the (D) position.
1. Place the manual control lever in the first gear position. Rotate the manual control lever forward
until travel stops. 2. Move the manual control lever back two detents to the (D) position.
6. Connect the transmission shift cable to the manual control lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 6145
7. Push in the transmission shift cable adjustment lock tab on the shift cable body. 8. Note: If
equipped with air suspension, reactivate the system by turning on the air suspension switch.
Lower the vehicle.
9. Remove the 3.6 kg (8 lb.) weight.
10. CAUTION: Do not adjust the transmission shift cable in any position other than (D).
Verify that the vehicle will start in P or N and that backup lamps illuminate in R. If not, repeat Steps
1 through 7 and perform a digital transmission range sensor alignment.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 6146
Shift Cable: Service and Repair
Removal
1. Disconnect the transmission shift cable from the steering column.
1. Disconnect the shift cable from the transmission column shift selector tube. 2. Disconnect the
shift cable from the steering column bracket.
2. Push the rubber grommet and transmission shift cable through the bulkhead. 3. Raise and
support the vehicle.
4. Remove the transmission shift cable from the automatic transmission.
1. Disconnect the shift cable from the manual control lever. 2. Depress lock tabs to release shift
cable and disconnect the shift cable from the shift cable bracket.
5. Remove the transmission shift cable bracket from the automatic transmission.
1. Remove the bolt. 2. Remove the transmission shift cable bracket.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Specifications > Page 6147
1. Note: The manual lever must be in the O/D position.
Follow the removal procedure in reverse order. Adjust the transmission shift cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Specifications > Page 6151
Torque Converter Clutch Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Specifications > Page 6152
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Specifications > Page 6153
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Specifications > Page 6154
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6157
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6158
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6159
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6160
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6161
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6162
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6163
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6164
Torque Converter Clutch Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6165
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6166
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6167
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6168
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6169
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6170
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6171
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 6172
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 6173
Torque Converter Clutch Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 6174
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 6175
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch
Solenoid, A/T > Component Information > Diagrams > Page 6176
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover >
Component Information > Specifications
Torque Converter Cover: Specifications
Converter housing screws 27-39 ft.lb
Converter housing-to-engine screws 30-41 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips
Transmission Cooler: Technical Service Bulletins A/T - Cooler Flushing Service Tips
Article No. 03-14-8
07/21/03
TRANSMISSION - NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS
FORD: 1992-1997 CROWN VICTORIA, PROBE, THUNDERBIRD 1992-2003 ESCORT,
MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2003 FOCUS 2002-2003
THUNDERBIRD 1992-1996 BRONCO 1992-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1992-1999 F-250 LD 1992-2003 ECONOLINE, EXPLORER, F-150, RANGER 1995-2003
WINDSTAR 1997-2003 EXPEDITION 1999-2003 SUPER DUTY F SERIES 2000-2003
EXCURSION 2001-2003 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN: 1992-1997 TOWN CAR 1992-2002 CONTINENTAL 1993-1998 MARK VIII 2000-2003
LS 1998-2003 NAVIGATOR 2002-2003 BLACKWOOD 2003 AVIATOR
MERCURY: 1992-1997 COUGAR, GRAND MARQUIS 1992-2000 TRACER 1992-2003 SABLE
1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2003 MOUNTAINEER
This article supersedes TSB 00-1-5.
ISSUE The number one cause for repeat transmission repairs is that contamination from the
transmission cooler system (lines and tank) will work their way back into the rebuilt or new
transmission. For this reason a new transmission cooler flusher has been released, "Turbo-Tank
Heated Cooler Line Flusher" Rotunda Tool number 22-00001.
ACTION The transmission cooling system (cooler and lines) MUST be flushed every time the
transmission is overhauled or replaced in order to minimize the likelihood of repeat repairs. The
use of this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001) is the most effective way to
remove contamination from its cooling system. Refer to the following Service Procedure and
Equipment instructions (supplied with the "Turbo-Tank Heated Cooler Line Flusher").
SERVICE PROCEDURE
Prior methods of cooler flushing have not obtained the level of cooler cleaning and contaminant
removal that is required to prevent repeat repairs. The "Turbo-Tank Heated Cooler Line Flusher"
uses heated Automatic Transmission Fluid (ATF) and a pulsating action to loosen system
contamination.
Previous equipment used solvents to clean & flush coolers, lines and torque-converters. There are
2 issues with this method:
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Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 6184
^ Residual solvent contamination can cause damage to friction bonding materials within the
transmission (Clutches and Bands).
^ Lack of fluid heating and agitation prevents this method from completely removing contamination
from lines, in-radiator coolers and auxiliary coolers.
Aerosol Solvents should never be used for several reasons.
^ They do not provide the volume necessary to remove heavy contaminants.
^ They evaporate quickly and essentially leave contaminants in pockets, bends, or wherever they
are as the solvent dries.
NOTE
YOU MUST IDENTIFY THE RETURN COOLER LINE TO START THE BACK FLUSHING
PROCEDURE.
A quick way to identify the return cooler line (fluid coming out of the cooler and returning to the
transmission) is to locate the return cooler line fitting on the transmission case. Refer to the
following lists:
Rear Wheel Drive
^ TORQSHIFT, 4R100, E40D, C6 - The REAR transmission case filling receives the return line.
^ 4R70W, AODE, AOD - The TOP transmission case filling receives the return line.
^ A4LD, 4R44/55E, 5R55E, 5R55N, 5R55W, 5R55S
- The TOP transmission case filling receives the return line.
Front Wheel Drive
^ CD4E - The REAR or Pump End transaxle case fitting receives the return line.
^ 4F27E - The REAR or Cover End transaxle case fitting receives the return line.
^ AXOD, AXODE, AX4S, AX4N, 4F50N - The BOTTOM transaxle cooler line fitting receives the
return line.
NOTE
IF AN IN-LINE FILTER HAS BEEN INSTALLED IN THE COOLER LINE, IT MUST BE REMOVED
BEFORE FLUSHING THE COOLER OR COOLER LINES.
Purge the cooler and cooler line before flushing:
Located on the "Turbo-Tank Heated Cooler Line Flusher" is a fluid transfer and purge valve. This
valve can be used to purge the cooler and cooler lines of contaminated fluid before starting the
back flush procedure of the fluid cooling system (refer to step 5a of this Service Procedure or
Equipment instructions, supplied with the "Turbo-Tank Heated Cooler Line Flusher").
Flush Procedure
1. Check and top off fluid level of the "Turbo-Tank Heated Cooler Line Flusher" tank with
transmission fluid.
2. Allow the fluid in the flusher 15-30 minutes to heat up to 140° F (60° C) before using.
3. Install line adapters into the transmission cooler lines.
4. Attach the flusher's blue line to the transmission return cooler line quick disconnect.
5. Attach the flusher's red line to the transmission outlet cooler line quick disconnect.
a. Follow equipment instructions, to purge cooler lines and cooler prior to starting flushing
procedure (using factory installed purge valve and clear hose on "Turbo-Tank Heated Cooler Line
Flusher").
6. Allow the cooling system to back-flush for 10-15 minutes, then flush the cooler in a
forward/normal flow direction for an additional 10-15 minutes.
For ordering information on this new "Turbo-Tank Heated Cooler Line Flusher" (222-00001),
contact Rotunda at 800-ROTUNDA (800-768-8632 or outside U.S. 262-656-5805).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > A/T - Cooler Flushing Service Tips > Page 6185
CAUTION
THIS FLUSHER CANNOT BE USED TO FLUSH COOLERS ON VEHICLES EQUIPPED WITH
THE TEMPERATURE BYPASS-TYPE TRANSMISSION COOLER CURRENTLY FOUND IN
1998-2003 CROWN VICTORIA, GRAND MARQUIS, AND TOWN CAR VEHICLES.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 00-1-5 WARRANTY STATUS:
INFORMATION ONLY
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Page 6186
Transmission Cooler: Specifications
Transmission Auxiliary Fluid Cooler Bolts 45 - 62 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Page 6187
Transmission Cooler: Service and Repair
Removal
1. Shut off the air suspension if equipped. 2. Disconnect the battery cables. 3. Raise and support
the vehicle.
4. Remove the radiator air deflector.
1. Remove the bolts. 2. Remove the radiator air deflector.
5. Place a drain pan under the transmission auxiliary fluid cooler.
6. Note: On 5.0L, the radiator must be loosened to provide access for removing the upper
transmission fluid cooler screw.
Loosen the two upper radiator hold down screws.
7. Remove the transmission auxiliary fluid cooler.
1. Disconnect the hoses. 2. Remove the bolts. 3. Remove the transmission auxiliary fluid cooler.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T >
Component Information > Technical Service Bulletins > Page 6188
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode Switch,
A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Specifications
Transmission Mount: Specifications
Transmission mount nuts to crossmember 64 - 81 ft.lb
Transmission mount-to-extension housing screws 64 - 81 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Specifications > Page 6198
Transmission Mount: Service and Repair
Removal
1. Note: 4x2 procedure shown. 4x4 similar, front drive shaft will need to be removed.
Disconnect the battery ground cable.
2. Raise and support the vehicle.
3. Note: To maintain initial driveshaft balance, mark the rear driveshaft yoke and axle flange so
they may be installed in their original alignment.
Mark the rear driveshaft.
4. Remove the rear driveshaft.
1. Remove the bolts. 2. Remove the rear driveshaft.
5. Remove the transmission mount nuts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Specifications > Page 6199
6. Raise and support the transmission.
7. Remove the transmission mount.
1. Remove the screws. 2. Remove the transmission mount.
Installation
1. Install the transmission mount.
1. Position the transmission mount on the extension housing. 2. Install the transmission
mount-to-extension housing screws.
2. Install the transmission mount into the crossmember and tighten the nuts.
3. Note: Align the driveshaft with the marks made during removal to ensure correct balance.
Align and install the rear driveshaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T >
Component Information > Specifications > Page 6200
4. Install the bolts. 5. Lower the vehicle. 6. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6204
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6205
Digital Transmission Range Sensor: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6206
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6207
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Digital Transmission Range
Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component Information > Specifications > Page 6208
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Specifications > Page 6212
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6215
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6216
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6217
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6218
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6219
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6220
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6221
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6222
Transmission Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6223
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6224
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6225
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6226
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6227
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6228
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6229
Transmission Speed Sensor: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6230
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 6231
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6234
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6235
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6236
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6242
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6243
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6244
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6245
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6246
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6247
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6248
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6249
Transmission Temperature Sensor/Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6250
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6251
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6252
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6253
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6254
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6255
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page 6256
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature
Sensor/Switch, A/T > Component Information > Diagrams > Page 6257
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No
2nd, 3rd Gear/No Engine Braking/DTC's Set
Valve Body: Customer Interest A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set
Article No. 03-22-10
11/10/03
TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT
WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733,
P1762 - VEHICLES BUILT BEFORE 12/1/2001
FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002
EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC
MERCURY: 1997-2001 MOUNTAINEER
This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage.
ISSUE
Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions:
^ No 2nd Gear
^ No 3rd Gear
^ No Engine Braking In Manual 1st.
Out of specification pressures controlled by the transmission main control valve body separator
plate may be the cause.
ACTION
Verify the condition, the main control valve body separator plate may need to be updated to the
latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No
2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6266
CAUTION
A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT
7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS
APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING.
NOTE
THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT
MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC
CONDITIONS.
NOTE
AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS
TSB.
1. Verify that one or more of the following conditions exist.
^ Low Line Pressure While In Drive At WOT
^ No 2nd And/Or No 3rd Gear
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 03-22-10 > Nov > 03 > A/T - No
2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6267
^ No Engine Braking In Manual 1st
^ DTC P0732, P0733 Or P1762
2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the
installation procedures found in the kit.
3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop
Manual, in-vehicle service, main control valve body.
4. After completing the procedure, verify the condition has been corrected.
5. Clear all DTCs.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 03-11-9, 02-13-8 02-08-2
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032210A Replace Separator Plate 2.8 Hrs.
And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve
Body And Diagnosis)
DEALER CODING
CONDITION
BASIC PART NO. CODE
D100 D8
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov >
03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set
Valve Body: All Technical Service Bulletins A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set
Article No. 03-22-10
11/10/03
TRANSMISSION - 4R44E - 4R55E - 5R44E - 5R55E - LOW LINE PRESSURE READING AT
WIDE OPEN THROTTLE (WOT) - POSSIBLE DIAGNOSTIC TROUBLE CODES P0732, P0733,
P1762 - VEHICLES BUILT BEFORE 12/1/2001
FORD: 1995-2001 EXPLORER 1995-2002 RANGER 1996-1997 AEROSTAR 2000-2002
EXPLORER SPORT 2001-2002 EXPLORER SPORT TRAC
MERCURY: 1997-2001 MOUNTAINEER
This article supersedes TSB's 03-11-9, 02-13-8 and 02-08-2 to update the model coverage.
ISSUE
Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions:
^ No 2nd Gear
^ No 3rd Gear
^ No Engine Braking In Manual 1st.
Out of specification pressures controlled by the transmission main control valve body separator
plate may be the cause.
ACTION
Verify the condition, the main control valve body separator plate may need to be updated to the
latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov >
03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6273
CAUTION
A NEW SEPARATOR 7Z490 MUST BE USED WHEN INSTALLING THE SPECIAL SERVICE KIT
7M203 OR ADDITIONAL TRANSMISSION DAMAGE MAY OCCUR. REFER TO THE PARTS
APPLICATION CHART IN THIS ARTICLE FOR CORRECT SEPARATOR PLATE PART LISTING.
NOTE
THIS ARTICLE DOES NOT APPLY TO ANY OTHER CONDITIONS OR COMPONENTS THAT
MAY CAUSE SIMILAR SYMPTOMS AND IS ONLY WRITTEN TO COVER THESE SPECIFIC
CONDITIONS.
NOTE
AN IN-LINE SERVICE FILTER IS NOT REQUIRED TO BE ADDED OR REPLACED FOR THIS
TSB.
1. Verify that one or more of the following conditions exist.
^ Low Line Pressure While In Drive At WOT
^ No 2nd And/Or No 3rd Gear
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-22-10 > Nov >
03 > A/T - No 2nd, 3rd Gear/No Engine Braking/DTC's Set > Page 6274
^ No Engine Braking In Manual 1st
^ DTC P0732, P0733 Or P1762
2. Install kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the
installation procedures found in the kit.
3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop
Manual, in-vehicle service, main control valve body.
4. After completing the procedure, verify the condition has been corrected.
5. Clear all DTCs.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 03-11-9, 02-13-8 02-08-2
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
032210A Replace Separator Plate 2.8 Hrs.
And Update Main Control Valve Body (Includes Time To Remove And Install Main Control Valve
Body And Diagnosis)
DEALER CODING
CONDITION
BASIC PART NO. CODE
D100 D8
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 6275
Valve Body: Specifications
Main control valve body screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 6276
Valve Body: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 6277
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly
Valve Body: Service and Repair Disassembly and Assembly
Special Tools
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6280
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6281
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6282
Disassembly
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6283
1. CAUTION: The SSC solenoid may pop out of its bore. This may damage the solenoid.
Remove the SSA and the SSC clamp and SSA and SSC solenoid. 1. Remove the solenoid clamp
screw. 2. Remove the solenoid clamp. 3. Remove the SSA and SSC solenoids.
2. CAUTION: The torque converter clutch solenoid (TCC) solenoid may pop out of its bore. This
may damage the solenoid.
CAUTION: The converter modulator valve may come out after the TCC solenoid. This may cause
damage to the valve.
Remove the SSB, SSD, torque converter clutch solenoid, and the EPC solenoid. 1. Remove the
solenoid clamp screw. 2. Remove the solenoid clamp. 3. Remove the SSB, SSD, torque converter
clutch solenoid and the EPC solenoids.
3. Rotate the main control valve body so that the main control to case gasket is facing up.
4. CAUTION: Valves may come out when rotating the main control valve body.
CAUTION: The extension housing lube orifice and relief valves may stick to the separator plate.
Note: Discard the main control to case gasket.
Remove the valve body separator plate screws. 1. Remove the main control to case gasket and
discard. 2. Remove the valve body separator plate screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6284
5. Remove valve body separator plate and main control to Separating plate gasket.
1. Remove valve body separator plate. 2. Remove main control to separator plate gasket and
discard.
6. Remove the extension housing lube orifice and the metal silver electronic pressure control (EPC)
limit relief valve and spring.
1. Remove the extension housing lube orifice. 2. Remove the silver metal EPC limit relief valve and
spring.
7. Remove the black plastic converter relief valve and spring.
8. Remove the electronic pressure control (EPC) limit circuit screen.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6285
9. Remove the four main control valve body check balls.
Assembly
1. CAUTION: Do not lose parts when cleaning or servicing.
Thoroughly clean all parts in solvent and blow dry with mo1sture free compressed air.
2. CAUTION: Do not stone, file, or sand the valves. This will remove the anodized finish and may
result in further main control or transmission
damage.
After cleaning the main control valve body, carry out the following: Inspect all valve and plug bores for scoring or burrs.
- Check all fluid passages for obstructions.
- Inspect all valves and plugs for burrs.
- Inspect all mating surfaces for burrs or d1stortion.
- Inspect all springs for d1stortion.
- Check all valves and plugs for free movement in their respective bores. Valves and plugs, when dry, must fall from their own weight into their respective bores.
- Roll the manual valve on a flat surface to cheek for a bent condition.
3. Clean and inspect the EPC solenoid screens.
4. Remove and replace all shift solenoid O-rings.
5. Clean and inspect the torque converter clutch solenoid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6286
6. CAUTION: Make sure that the screen is properly located.
Clean and inspect the electronic pressure control (EPC) limit circuit screen. Install the EPC limit
circuit screen.
7. Install the four main control valve body check balls.
8. CAUTION: The springs and valves are not interchangeable. Damage to transmission may occur.
Install the dark color plastic converter relief valve and spring.
9. Note: The springs and valves are not interchangeable.
Install the extension housing lube orifice and the metal silver electronic pressure control (EPC) limit
relief valve and spring. 1. Install the extension housing lube orifice. 2. Install the silver metal EPC
limit relief valve and spring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6287
10. Note: Apply petroleum jelly on the valve body separator plate to hold the main control to
separator plate gasket in place.
Note: Use new separator plate main control to separator plate gasket on installation.
Install the main control valve body separator plate and gasket to the main control. 1. Position the
main control valve body separator plate to the main control gasket and install separator plate to
main control valve body. 2. Install, do not tighten, the three screws.
11. Install the Valve Body Aligner into the main control valve body.
1. Install the Valve Body Aligner (0.248). 2. Install the Valve Body Aligner (0.235).
12. Tighten the screws.
13. Note: Apply petroleum jelly on the separator plate surface to hold the gasket in place.
Note: Use new separator plate gasket on installation.
Install new main control to case gasket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6288
14. Remove the Valve Body Aligner from the main control valve body.
1. Remove the Valve Body Aligner (0.248). 2. Remove the Valve Body Aligner (0.235).
15. Rotate the main control valve body so the valve body separator plate is facing down.
16. CAUTION: All solenoid electrical connectors must face upward on installation.
Note: All shift solenoids are interchangeable.
Note: If the TCC valve came out during disassembly, use caution when installing the torque
converter clutch solenoid.
Install the SSB, SSD, TCC and EPC solenoids. 1. Install the TCC solenoid. 2. Install the SUB and
SSD solenoids. 3. Install the EPC solenoid.
17. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp and the screw. 1. Position the solenoid clamp on the main control valve
body. 2. Install the screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6289
18. CAUTION: The shift solenoid electrical terminals must face up on installation.
Note: The shift solenoids are interchangeable.
Install the SSA and the SSC shift solenoids.
19. Install the solenoid clamp and the screw.
1. Position the solenoid clamp on the main control valve body. 2. Install the screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6290
Valve Body: Service and Repair Removal and Installation
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Place a drain pan
under the transmission fluid pan.
4. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
5. Drain transmission fluid.
Remove all the transmission fluid pan bolts except for two in the front. Loosen the two front
transmission fluid pan bolts. Pry the rear of the transmission fluid pan down and allow fluid to drain.
After fluid is drained remove the front two transmission fluid pan bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6291
6. Note: If a transmission has been disassembled to replace worn or damaged parts and the valves
in the main control valve body stick repeatedly
from foreign material, the torque converter must be removed and cleaned by using a suitable
torque converter/fluid cooler cleaner.
Remove the transmission fluid pan. 1. Remove the transmission fluid pan. 2. Remove and discard
the transmission fluid pan gasket.
7. Remove and discard the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
8. Unclip main control valve body wire harness.
- Lift up on wire harness guide and protector and disengage the retaining pins from the solenoid
clamps.
9. Disconnect the six solenoid electrical connectors.
1. Disconnect the SSA, SSB, SSC and SSD electrical connectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6292
2. Disconnect the torque converter clutch (TCC) solenoid electrical connector. 3. Disconnect the
electronic pressure control (EPC) solenoid electrical connector.
10. Remove the manual control valve detent lever spring.
1. Remove the manual control valve detent lever spring screw. 2. Remove the manual control valve
detent lever spring.
11. Remove the low/reverse servo.
1. Remove the low/reverse servo cover screws. 2. Remove the low/reverse band servo cover and
gasket. Discard the low/reverse servo separator plate cover gasket.
12. Remove the low/reverse band servo piston and rod.
13. CAUTION: Support the main control valve body. Do not remove the two (gold) screws
specified.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6293
14. CAUTION: Support the main control valve body. Remove the screws.
15. Remove the main control valve body.
Installation
1. Install the Valve Body Aligner into the transmission case.
1. Install the Valve Body Aligner (0.248). 2. Install the Valve Body Aligner (0.235).
2. Note: Make sure main control to case gasket is properly aligned.
Install new main control to case gasket.
3. Position the main control valve body with the two Valve Body Aligners as a guide.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6294
4. Note: The main control valve body screws will be tightened in later steps.
Loosely install four M6 x 45 mm (1.8 inch) screws.
5. Note: The main control valve body screws will be tightened in later steps.
Loosely install two M6 x 35 mm (1.4 inch) screws.
6. Remove the Valve Body Aligners.
7. Note: The main control valve body screws will be tightened in later steps.
Loosely install the M6 x 30 mm (1.2 inch) screw.
8. Note: The main control valve body screws will be tightened in later steps.
Loosely install the sixteen M6 x 40 mm (1.6 inch) main control valve body screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6295
9. Tighten the main control valve body screws in the sequence shown.
10. Install the manual control valve detent lever spring.
11. Install the low/reverse band servo piston and rod.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6296
12. Install the low/reverse band servo cover.
1. Install the low/reverse band servo cover and gasket. 2. Loosely install the low/reverse servo
piston cover screws.
13. Tighten the servo cover screws in the sequence shown.
14. Connect the six solenoid electrical connectors.
1. Connect SSA, SSB, SSC, and SSD electrical connectors. 2. Connect the torque converter clutch
(TCC) solenoid electrical connector. 3. Connect the electronic pressure control (EPC) solenoid
electrical connector.
15. CAUTION: Excessive pressure may break the locating pins.
Install the main control valve body wire harness. Align the retaining pins to the holes in the solenoid clamps and press in the main control valve body
wire harness guide and protector.
16. Install the transmission fluid filter.
1. Install the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Disassembly and Assembly > Page 6297
2. Install the transmission fluid filter screw.
17. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Install and align
the transmission fluid pan.
18. Tighten the transmission fluid pan screws.
- Use a crisscross sequence to tighten the transmission fluid pan screws.
19. Position the servo heat shield over the servos and clip it to the pan rail. 20. Lower the vehicle.
21. Connect the battery ground cable. 22. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair
Wiring Harness: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle. 3. Disconnect vehicle
harness from transmission case (16 pin) connector. 4. Drain the transmission fluid.
5. Note: The main control assembly does not need to be removed.
Remove the transmission fluid filter. 1. Remove the transmission fluid filter screw. 2. Remove the
transmission fluid filter.
6. Remove main control valve body wire loom.
- Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
7. Disconnect the solenoid electrical connectors.
1. Disconnect the SSA, SSB, SSC, and the SSD electrical connectors. 2. Disconnect the torque
converter clutch (TCC) solenoid electrical connector. 3. Disconnect the electronic pressure control
(EPC) solenoid electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6301
8. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoids may pop out of their bore. This may damage the solenoids.
Remove the EPC and SSB solenoids. 1. Remove the solenoid clamp bolts. 2. Remove the solenoid
clamp. 3. Remove the EPC and SSB solenoids.
9. CAUTION: Do not pry on the other wires or damage the connector case surface.
Disconnect the turbine shaft speed (TSS) sensor electrical connector from the transmission case
(16 pin) electrical connector. 1. Disconnect the TSS sensor electrical connector. 2. Remove from
the TSS sensor wire locator.
10. CAUTION: Do not overstretch the retaining spring.
Remove the transmission case (16 pin) electrical connector retaining spring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6302
11. CAUTION: Do not damage the connector or harness.
Remove the transmission case (16 pin) electrical connector. Compress the tabs on the transmission case (16 pin) electrical connector.
- Push the transmission case (16 pin) electrical connector out of transmission case.
Installation
1. Note: Make sure the tab is in the lock position.
Note: Install new O-rings on the transmission case (16 pin) electrical connector.
Install the transmission case (16 pin) electrical connector. Lubricate the transmission case (16 pin) electrical connector O-rings with petroleum jelly.
2. Press the transmission case (16 pin) electrical connector through the case until a click is heard.
3. CAUTION: Align the slot on the TSS sensor electrical connector with the slot in the 16 pin case
connector.
Install the TSS sensor wire. 1. Install TSS sensor wire into (16 pin) case connector. 2. Install TSS
sensor wire into the locator.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6303
4. CAUTION: Do not overstretch the retaining spring.
Install the transmission case (16 pin) electrical connector retaining spring.
5. Install the EPC and SSB solenoids.
6. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6304
7. Connect the SSA and SSC shift (SS) solenoid electrical connectors.
8. Connect the TCC, SSD, SSB, and EPC solenoid electrical connectors.
9. CAUTION: Excessive pressure may break the retaining pins.
Install the wire harness guide and protector. Align the retaining pins to the holes in the solenoid clamps and gently press in the wire harness
guide and protector.
10. Install the transmission fluid filter.
1. Install the transmission fluid filter. 2. Install the transmission fluid filter screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T >
Component Information > Service and Repair > Page 6305
11. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
12. Tighten the transmission fluid pan screws. 13. Connect vehicle harness to transmission (16 pin)
connector. Make sure lock is fully engaged. 14. Lower the vehicle. 15. Connect the battery ground
cable. 16. Fill the transmission to the proper fluid level and check for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Specifications
Clutch Disc: Specifications
O.S. Diameter (approx.) 10.2 in
I.S. Diameter (approx.) 7.3 in
Facing Area Sq. cm (sq. in) 508 (787)
Compressed Thickness 0.307 in
Lining Material Woven non-asbestos
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Specifications > Page 6310
Clutch Disc: Service and Repair
Special Tools
Removal
1. Remove the transmission.
2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed
evenly or permanent damage to the diaphragm
spring win occur resulting in complete clutch release.
Remove the clutch pressure plate and clutch disc. 1. If the parts are to be reused, mark the clutch
pressure plate and flywheel. 2. Remove the bolts. 3. Remove the clutch pressure plate and clutch
disc.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Specifications > Page 6311
1. Note: Self-adjusting clutch pressure plate must be adjusted before installation.
Compress the clutch diaphragm fingers. 1. Place the (A) flywheel and the (B) clutch pressure plate
in a press. 2. Use a (C) suitable adapter and a (D) press to depress the (E) clutch diaphragm
fingers until the adjusting ring moves freely.
2. Adjust the clutch pressure plate.
- Rotate the (A) adjusting ring counterclockwise until the (B) tension springs are compressed.
- Hold the (A) adjusting ring while releasing the pressure on the clutch fingers.
3. Position the (A) clutch disc on the (B) flywheel using the (C) Clutch Aligner.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information >
Specifications > Page 6312
4. Note: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate on three dowels. 1. Align the clutch pressure plate and install the
clutch pressure plate bolts. 2. Remove Clutch Aligner.
5. Install the transmission.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Fluid >
Component Information > Specifications
Clutch Fluid: Specifications
Clutch Fluid Type DOT-3 Brake Fluid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Specifications
Clutch Master Cylinder: Specifications
Clutch Master Cylinder Reservoir Bolts 16 - 23 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Specifications > Page 6320
Clutch Master Cylinder: Service and Repair
Special Tool(s)
Special Tool
Clutch Master Cylinder/Reservoir
Removal and Installation 1. Raise and support the vehicle.
2. Using the special tool, disconnect the hydraulic line from the clutch slave cylinder. 3. Lower the
vehicle.
4. Disconnect the clutch pedal position (CPP) switch electrical connector.
5. Disconnect the clutch master cylinder rod from the clutch pedal arm. Remove and discard the
clutch master cylinder push rod bushing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Specifications > Page 6321
6. Remove the CPP switch.
- Pinch the lock tabs and pull the clip forward. Rotate and snap the CPP switch from the clutch
master cylinder rod.
7. Remove the reservoir.
8. Remove the three pushpins, four bolts, four screws and the inner fender splash shield. 9. Unclip
the hydraulic line-to-frame retainer.
10. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, wash the surface with
water immediately. Unlock and remove the clutch master cylinder assembly. Twist the clutch master cylinder clockwise 45 degrees to unlock it from the support bracket.
- Remove the reservoir the hydraulic line and the clutch master cylinder as an assembly. Install a
new clutch master cylinder push rod bushing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Master Cylinder >
Component Information > Specifications > Page 6322
11. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, wash the surface with
water immediately. To install, reverse the removal procedure. Bleed the clutch hydraulic system. Rotate the clutch master cylinder 45 degrees counterclockwise.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Specifications
Clutch Slave Cylinder: Specifications
Clutch Slave Cylinder Bolts 13 - 17 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Specifications > Page 6326
Clutch Slave Cylinder: Service and Repair
Removal
1. Disconnect the clutch master cylinder hydraulic line from the clutch slave cylinder with (A) Clutch
Coupling Tool. 2. Remove the transmission.
3. Note: Inspect the clutch housing for traces of fluid. If fluid is visible, replace the clutch slave
cylinder.
Remove the clutch slave cylinder. 1. Remove the bolts. 2. Remove the clutch slave cylinder.
4. CAUTION: The clutch release hub and bearing is prelubricated and should not be cleaned with
solvent. The clutch release hub and bearing are
replaced as an assembly. Do not disassemble for inspection or replacement.
Remove the clutch release hub and bearing from the clutch slave cylinder. 1. Push the clutch
release hub and bearing against the spring and move toward the base. 2. Remove the retainer ring
and remove the clutch release hub and bearing and the spring.
5. Inspect the clutch slave cylinder for the following:
- Weak spring.
- Leaking fluid.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder >
Component Information > Specifications > Page 6327
1. Install the clutch release hub and bearing.
- Lubricate the clutch release hub and bearing at sliding points with Premium Long-Life Grease
XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B.
1. Position the (A) spring and the (B) clutch release hub and bearing onto the clutch slave cylinder.
2. Push the clutch release hub and bearing against the spring and install the retainer ring.
2. Install the clutch slave cylinder.
1. Position the clutch slave cylinder. 2. Install the bolts.
3. Install the transmission.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Service and Repair
Hydraulic Hose: Service and Repair
Removal
1. Raise and support the vehicle. 2. Disconnect the line from the plastic clip at the floor flange.
3. Uncouple the lower end of the clutch master cylinder hydraulic line from the clutch slave cylinder
using (A) Clutch Coupling Tool. 4. Lower the vehicle. 5. Remove the clutch master cylinder and the
hydraulic line assembly.
6. Remove and discard the roll pin holding the line to the clutch master cylinder.
7. Note: Check that the O-ring is still in the outlet port of the clutch master cylinder. If not, replace.
Disconnect the line from the clutch master cylinder by applying a slight tug on the line.
Installation
1. Insert the new line into the clutch master cylinder outlet port.
2. Install clutch master cylinder tube.
1. Position line and install roll pin. 2. Tug on clutch master cylinder tube.
3. Raise and support the vehicle. 4. Bleed the system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Service and Repair > Page 6331
5. Note: Check that the O-ring is in place on the line. Check the clutch slave cylinder port to be sure
there is no O-ring.
Insert the male coupling end into the female coupling of the clutch slave cylinder. Check that the connection is secure by applying a slight tug to the line.
6. Connect the line to the plastic clip on the floor flange. 7. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Hydraulic Hose, Clutch
> Component Information > Service and Repair > Page 6332
Hydraulic Hose: Tools and Equipment
Clutch Line Fork
AST tool# 8008
Used for the R and R of the hydraulic clutch line from the internally mounted slave cylinder. This
tool is applicable to the following Ford vehicles with manual transmissions: 1989 and later Ford
Aerostar, Bronco II, Explorer, F150 and Ranger.
- For R and R of Hydraulic Clutch Lines
- Applicable to Ford Models with Manual Transmissions
- Steel Construction
- Black-Oxide Finish
Contact AST for pricing.
Assenmacher Specialty Tools 1-800-525-2943
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information >
Service and Repair
Clutch Pedal Assembly: Service and Repair
Removal
1. CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface wash it immediately
with water.
Disconnect the clutch master cylinder push rod.
2. Remove the retainer ring.
3. Note: When the clutch pedal shaft is removed from the bracket, the brake pedal, brake and
clutch pedal bushings, and spring washer become
accessible.
Remove the clutch pedal from the pedal support bracket.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Assembly > Component Information >
Service and Repair > Page 6336
1. Note: Before the installation of the clutch pedal shaft or clutch pedal, remove and inspect the
brake and clutch pedal bushings. Clean and
lubricate with a light film of SAE 30 engine oil X0-30-BSD or equivalent ESE-M2C153-E and
replace the brake and clutch pedal bushing if excessive wear is evident.
Install the clutch/brake pedal assembly. Install the clutch/brake pedal bushings and washers and the clutch pedal.
- Install the clutch pedal shaft.
2. Install the retainer ring.
3. Install the clutch master cylinder push rod to pedal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Switch > Component Information >
Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service
and Repair
Pilot Bearing: Service and Repair
Special Tools
Removal
1. Note: Only replace the transmission input shaft pilot bearing if it is damaged.
Remove the transmission input shaft pilot bearing using Impact Slide Hammer and Puller.
2. Inspect the transmission input shaft pilot bearing for:
- misalignment and looseness in the flywheel.
- needle rollers for scoring, worn or broken needle rollers, inadequate grease or discoloration.
- seal leakage.
3. CAUTION: To prevent damage, do not use cleaners with a petroleum base and do not immerse
the clutch pressure plate in solvent.
Clean the clutch pressure plate using a suitable commercial alcohol-based solvent so surface is
free from oil film.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pilot Bearing > Component Information > Service
and Repair > Page 6343
1. Note: The transmission input shaft pilot bearing can only be installed with the seal facing the
transmission. The transmission input shaft pilot
bearing is pregreased and does not require additional lubrication. A new transmission input shaft
pilot bearing must be installed whenever it is removed.
Install the (A) transmission input shaft pilot bearing using (B) Pilot Bearing Replacer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications
Pressure Plate: Specifications
Clutch Pressure Plate Bolts 17 - 23 ft.lb
Total Plate Pressure 2248-315 lbf
Diaphragm Spring Belleville
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications > Page 6347
Pressure Plate: Service and Repair
Special Tools
Removal
1. Remove the transmission.
2. CAUTION: If the clutch disc and pressure plate are to be reinstalled, bolts must be removed
evenly or permanent damage to the diaphragm
spring win occur resulting in complete clutch release.
Remove the clutch pressure plate and clutch disc. 1. If the parts are to be reused, mark the clutch
pressure plate and flywheel. 2. Remove the bolts. 3. Remove the clutch pressure plate and clutch
disc.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications > Page 6348
1. Note: Self-adjusting clutch pressure plate must be adjusted before installation.
Compress the clutch diaphragm fingers. 1. Place the (A) flywheel and the (B) clutch pressure plate
in a press. 2. Use a (C) suitable adapter and a (D) press to depress the (E) clutch diaphragm
fingers until the adjusting ring moves freely.
2. Adjust the clutch pressure plate.
- Rotate the (A) adjusting ring counterclockwise until the (B) tension springs are compressed.
- Hold the (A) adjusting ring while releasing the pressure on the clutch fingers.
3. Position the (A) clutch disc on the (B) flywheel using the (C) Clutch Aligner.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information >
Specifications > Page 6349
4. Note: If reusing the clutch pressure plate and flywheel, align the marks made during removal.
Position the clutch pressure plate on three dowels. 1. Align the clutch pressure plate and install the
clutch pressure plate bolts. 2. Remove Clutch Aligner.
5. Install the transmission.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Service and Repair
Carrier Bearings: Service and Repair
AXLE TUBE BEARING, SOLID REAR AXLE
Special Service Tool(s)
Removal
1. Remove the right-hand halfshaft.
2. Remove the right-hand axle shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Service and Repair > Page 6355
3. Use a converter oil seal remover and a slide hammer to remove the axle seal.
4. Use an axle bearing remover and a slide hammer to remove the axle tube bearing. 5. Clean the
bearing and seal surfaces of any foreign debris.
Installation
1. Use the Axle Bearing Replacer and the Handle to replace the RH axle tube bearing.
2. Check the bearing depth as shown.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Carrier > Carrier Bearings >
Component Information > Service and Repair > Page 6356
3. Use the Axle Seal Replacer and the Handle to replace the axle tube seal.
4. CAUTION: Care should be taken not to damage the axle seal surface.
Install the axle shaft.
5. Refill the front drive axle to proper level using Motorcraft SAE 80W90 Thermally Stable 4x4 Axle
Lubricant meeting Ford specification
WSP-M2C197-A.
6. Install the RH halfshaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Specifications
Differential Case: Specifications
Maximum differential case runout
................................................................................................................................................ 0.076
mm (0.003 inch)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front
Differential Case: Service and Repair Front
Special Tools
Disassembly
1. Remove the differential ring gear.
1. Remove and discard the bolts. 2. Using a drift that will bottom out in the bolt holes, separate the
differential ring gear from the differential case.
2. Drive out the differential pinion shaft roll pin.
3. Remove the differential pinion shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6362
4. CAUTION: The upper differential side gear may fall out of the case bore after removing the
differential pinion gears.
Rotate the differential pinion gears to the differential case window and remove them and the
differential pinion thrust washers.
5. Remove the differential side gears and the differential side gear thrust washers.
6. Assemble the special tool.
7. Position the special tool on the differential bearing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6363
8. Using the special tool, remove the differential bearing.
- Repeat the procedure for the other bearing.
Assembly
1. Lubricate the differential side gear thrust washers and the differential side gears, and assemble
them.
- Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification
WSP-M2C197-A.
2. Position the differential side gear and thrust washer assemblies in the differential case.
3. Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble
them.
- Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification
WSP-M2C197-A.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6364
4. Engage the differential pinion gears between the differential side gears.
5. Rotate the differential pinion gears and align them with the differential pinion shaft bore.
6. Insert the differential pinion shaft.
7. Install the differential pinion shaft roll pin. 8. install the differential bearing shims, the differential
bearings, and the differential ring gear.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6365
Differential Case: Service and Repair Rear
Differential Case and Ring Gear-Conventional
Special Tools
Disassembly
1. Remove the differential case.
2. Remove the 10 ring gear bolts.
3. CAUTION: Care should be taken not to damage the bolt hole threads.
Insert a punch in the bolt holes and drive the ring gear off.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6366
4. Note: The speed sensor ring cannot be reused once removed.
Remove the speed sensor ring if required.
5. If required, use the special tools to remove the differential bearings.
6. Remove the differential pinion shaft lock bolt.
7. Remove the differential pinion shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6367
8. Rotate and remove the differential pinion gears and the differential pinion thrust washers.
9. Remove the differential side gears and the differential side gear thrust washers.
Assembly
1. Lubricate the differential side gear thrust washers and the differential side gear journals.
- For vehicles with 5.0L engines, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B meeting Ford specification WSL-M2C192-A.
- For vehicles with 4.0L engines, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL
meeting Ford specification WSP-M2C197-A.
- Position thee differential side gear thrust washers on the differential side gears.
2. Position the differential side gears.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6368
3. Lubricate the differential pinion thrust washers and the differential pinion gears and assemble.
- For vehicles with 5.0L engines, use SAE 75W-140 High Performance Rear Axle Lubricant
F1TZ-19580-B meeting Ford specification WSL-M2C192-A.
- For vehicles with 4.0L engines, use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL
meeting Ford specification WSP-M2C197-A.
4. Engage the differential pinion gears opposite the differential side gears.
5. Rotate the differential pinion gears to align with the differential pinion shaft bore.
6. Insert the differential pinion shaft.
- Align the hole in the differential pinion shaft with the hole in the differential case.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6369
7. CAUTION: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and
Sealer EOAZ-19554-AA or equivalent meeting
Ford specifications WSK-M2G351-A5 prior to installation.
Install a new differential pinion shaft lock bolt and tighten finger-tight.
8. Using the special tool, install the new differential bearings on the differential case.
9. Press the new anti-lock speed sensor ring and the ring gear on the differential case.
10. Install the ring gear bolts.
- Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification
WSK-M2G349-A1 to ring gear bolts.
11. Install the differential case.
Differential Case and Ring Gear-Traction-LOK
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6370
Special Tools
Special Tools
Disassembly
1. Remove the differential case.
2. Remove the 10 bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6371
3. CAUTION: Do not damage the bolt hole threads.
Insert a punch in the bolt holes, and drive the ring gear off.
4. CAUTION: Do not reuse the anti-lock speed sensor ring after removing it.
If necessary, remove the anti-lock speed sensor ring and discard it.
5. Using the special tools, remove the differential bearings.
6. Remove the differential pinion shaft lock bolt, and remove the differential pinion shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6372
7. WARNING: Due to the spring tension, take care when removing the differential clutch spring.
Remove the differential clutch spring.
8. Remove the differential gears and washers.
1. Remove the differential pinion gears. 2. Remove the differential side gears. 3. Remove the
differential pinion thrust washers
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6373
9. CAUTION: Keep the differential clutch packs in order. Do not mix them. Be sure to reassemble
them in the same sequence.
Remove and tag the differential clutch packs, shims and differential side gears "right" and left".
10. CAUTION: Do not use acids or solvents to clean the differential clutch packs. Wipe the
components with a clean, lint-free cloth only.
Clean and inspect the differential clutch packs for wear and damage. Install new parts as
necessary.
11. Clean and inspect the remaining differential case components for wear and damage. Install
new components as necessary.
Assembly
1. CAUTION: Use 118 ml. (4 oz.) of Ford Additive Friction Modifier C8AZ-19B546-A or equivalent
meeting Ford specification EST-M2C118-A
in the axle.
Prelubricate each steel clutch plate and soak all of the friction plates in Ford Additive Friction
Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST-M2C118-A for at least 15
minutes.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6374
2. CAUTION: Do not mix the left and right side differential clutch packs and shims.
Assemble the left and right differential clutch packs (without the shims) and differential side gears.
3. CAUTION: Use the correct mandrel with the Differential Clutch Gauge.
Place the special tool in a vise.
4. Install the differential clutch pack and differential side gear (without the shim) on the special tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6375
5. Position the special tool hand-tight on top of the differential clutch pack.
6. Install the special tool over the disc and differential clutch pack.
7. Install the nut.
8. Note: Clutch Pack Kit FSAZ-4947-BA is available to rebuild the 8.8-inch ring gear Traction-Lok
differential.
Using the special tool, determine the thickness of the new clutch shim. Insert the thickest blade that will enter between the tool and the differential clutch pack.
Selective Shims
9. Remove the special tool from the clutch pack and side gear assembly.
10. Install the shims on the clutch pack and side gear assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6376
11. Install the differential side gear assemblies in the differential case.
12. Install the differential pinion gears with the differential pinion thrust washers in the differential
case.
13. Using a soft-faced hammer, install the differential clutch spring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6377
14. Install the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.
15. Using the special tool, install the differential bearings.
16. Install the anti-lock speed sensor ring by aligning the tab with the slot.
- Start two bolts through the differential case and into the ring gear to make sure the ring gear bolt
holes align with the differential case bolt holes.
17. Press the new anti-lock speed sensor ring and the ring gear on the differential case.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6378
18. Install the bolts.
- Apply Stud and Bearing Mount EOAZI9554-BA or equivalent meeting Ford specification
WSK-M2G349-AI to the bolt threads.
19. Install the differential case.
Removal and Installation
Special Tools
Special Tools
Special Service Tool(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6379
Removal
1. Remove the axle shafts. 2. Wipe the lubricant from the internal working parts and visually inspect
the parts for wear and damage.
3. Rotate the differential case to see if there is any roughness which would indicate damaged
bearings or gears.
4. Note: There is a space between the anti-lock speed sensor ring and the ring gear for measuring
ring gear backface runout.
Position the special tool and check the ring gear backlash and ring gear backface runout.
5. CAUTION: Mark the position of the bearing caps, as the arrows may not be visible. The bearing
caps must be installed in their identical
locations and positions.
Loosen the differential case. 1. Remove the four bearing cap bolts. 2. Remove the two bearing
caps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6380
6. WARNING: Be careful not to allow the differential case to fall.
CAUTION: Place a wood block between the pry bar and the rear axle housing to protect the
machined surface from damage.
Use the pry bar and the wood block to remove the differential case from the rear axle housing.
7. Remove the 10 ring gear bolts.
8. CAUTION: Care should be taken not to damage the ring bolt hole threads.
CAUTION: The anti-lock speed sensor ring cannot be reused once removed.
Insert a punch in the bolt holes and drive off the ring gear and, if necessary, the anti-lock speed
sensor ring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6381
9. Install the differential case.
- Position the differential case assembly, including the bearing cups and shims, in the rear axle
housing. Install the differential bearing caps and the differential bearing cap bolts.
10. Position the special tool.
1. Rotate the differential case to make sure the differential bearings are correctly seated. 2.
Position the special tool.
11. Note: If runout is less than the specification, install a new ring gear and pinion. If runout
exceeds the specification, the ring gear is true and the
concern is due to either a damaged differential case or differential bearings. Inspect the differential
bearings. If the differential bearings are not damaged, install a new differential case and differential
bearings.
Measure the differential case runout without the ring gear.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6382
12. Remove the differential case from the rear axle housing and remove the differential bearings
using the special tools.
13. Use the special tool to install the new differential bearings on the differential case.
14. Install the differential case. Position the differential case assembly, including the bearing cups
and shims in the rear axle housing. Tighten bearing
caps to specifications.
15. Measure the differential case runout without the ring gear, and check the case runout again
with the new differential bearings.
- If the runout is now less than the specification shown, use the new differential bearings for
assembly.
- If the runout is still excessive, the differential case is damaged and a new differential case must
be installed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6383
Installation All vehicles
1. Press a new anti-lock speed sensor ring, if removed, and the ring gear on the differential case.
- Align the notch on the differential case flange with the notch on the anti-lock speed sensor ring.
2. Install the ring gear bolts.
- Apply Stud and Bearing Mount EOAZ-19554-BA or equivalent meeting Ford specification
WSK-M2G349-AI to ring gear bolts.
3. With pinion depth set and pinion installed, place the differential case in the rear axle housing.
4. Install a shim on the left side.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6384
5. CAUTION: Mark the position of the bearing caps as the arrows may not be visible. The bearing
caps must be installed in their identical locations
and positions.
Note: Apply pressure toward the left side to make sure the left bearing cap is seated.
Install the left bearing cap and loosely install the bearing cap bolts.
6. Install progressively larger shims on the right side until the largest shim selected can be
assembled by hand.
7. Install the right side bearing cap and tighten the left side and right side bolts to specification.
8. Rotate the differential case to make sure it rotates freely.
Measuring backlash
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6385
9. Use the special tool to measure the ring gear backlash.
- If the backlash is within specification, go to Backlash within specification in this procedure.
- If a zero backlash condition occurs, go to Zero backlash in this procedure.
- If the backlash is not within specification, go to Backlash not within specification in this procedure.
Zero backlash
10. If a zero backlash condition occurs, add 0.51 mm (0.020 inch) to the RH side and subtract 0.51
mm (0.020 inch) from the LH side to allow
backlash indication. Cheek the backlash. Repeat Measuring backlash in this procedure.
Backlash not within specification
11. To increase or decrease the backlash, remove the bearing caps and install a thicker shim or a
thinner shim as shown.
- If the backlash is not within specification, correct by increasing the thickness of one differential
bearing shim and decreasing the thickness of the other differential bearing shim by the same
amount.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6386
12. Rotate the differential several times to make sure the differential bearings are correctly seated.
13. Using the special tool, recheck the backlash.
- If the backlash is within specification, go to Backlash within specification in this procedure. If the
backlash is not within specification, repeat measuring backlash in this procedure.
Backlash within specification
14. Remove the bearing caps and bolts.
- To establish differential bearing preload, increase both left and right shim sizes by the
specification shown in the illustration.
- Using the special tool, make sure that the differential bearing shims are fully seated and the
assembly turns freely.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component
Information > Service and Repair > Front > Page 6387
15. Install the bearing caps and bearing cap bolts.
16. Using the special tool, recheck the backlash. 17. Install the axle shafts. 18. Install the
differential housing cover and refill the rear axle with specified lubricant.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Technical Service Bulletins > Customer Interest for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain Front Drive Axle Vent Tube Fluid Leaks
Differential Cover: Customer Interest Drivetrain - Front Drive Axle Vent Tube Fluid Leaks
TSB 05-6-20
04/04/05
FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD
FORD: 1995-2001 Explorer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer
Sport Trac
MERCURY: 1997-2001 Mountaineer
This article supersedes TSB 03-05-08 to update the model year applications and to revise the
Service Procedure.
ISSUE Some Explorer/Mountaineer, Ranger and Explorer Sport/Sport Trac 4x4/AWD vehicles,
may exhibit a fluid leak from the front axle vent tube. This may be caused by fluid being thrown
toward the axle vent by the gears during vehicle operation.
ACTION Install a revised front axle cover kit. The revised cover has a baffle built in to reduce the
possibility of fluid being thrown out of the vent during vehicle operation. Refer to the following
Service Procedure.
SERVICE PROCEDURE
NOTE
DO NOT FOLLOW THE SERVICE PROCEDURE OUTLINED IN THE DANA/SPICER
INSTRUCTION SHEET INCLUDED IN THE COVER KIT. FOLLOW THE TSB SERVICE
PROCEDURE.
1. With the vehicle in NEUTRAL, raise and support the vehicle.
2. Remove the lower engine splash shield, if equipped.
3. Index-mark the front axle pinion flange and the front driveshaft.
4. Remove the driveshaft bolts and retainers. Discard the driveshaft bolts.
5. Tape the U-joint bearing caps to prevent them from falling off the U-joint.
6. Swing the driveshaft away from the axle pinion yoke and secure out of the way.
7. Remove the three (3) axle support mounting bracket bolts from the axle housing.
8. Position suitable jack beneath axle housing.
NOTE
PLACE FOLDED SHOP TOWELS OR SUITABLE SOFT MATERIAL OVER TORSION BARS TO
PROTECT THE HALFSHAFT BOOTS AND CLAMPS FROM DAMAGE.
9. Remove the two (2) bolts and nuts from the front axle support bushings. Discard the nuts.
10. Carefully lower and position the axle housing until it is resting on the torsion bars.
11. Disconnect the vent hose from the axle housing.
12. Position a drain pan under the axle housing cover. Rotate the axle housing slightly to allow
easy access to the axle cover bolts. Remove the axle housing cover and discard.
13. Clean the axle housing cover mounting surface.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Technical Service Bulletins > Customer Interest for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain Front Drive Axle Vent Tube Fluid Leaks > Page 6396
14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing
surface.
15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the
cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m).
16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the
kit (Figure 1).
17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit.
18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque
the bolts to 49 lb-ft (66 N.m).
19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106
N.m).
20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m).
21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90
Premium Rear Axle Lubricant. Install fill plug.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050620A 1995-2001 Explorer 1.5 Hrs.
1997-2001 Mountaineer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport
Trac: Install A Revised Axle Cover Kit
DEALER CODING
CONDITION
BASIC PART NO. CODE
4022 D1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Technical Service Bulletins > Customer Interest for Differential Cover: > 05-6-20 > Apr > 05 > Drivetrain Front Drive Axle Vent Tube Fluid Leaks > Page 6397
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Cover: > 05-6-20 > Apr > 05 >
Drivetrain - Front Drive Axle Vent Tube Fluid Leaks
Differential Cover: All Technical Service Bulletins Drivetrain - Front Drive Axle Vent Tube Fluid
Leaks
TSB 05-6-20
04/04/05
FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4 OR AWD
FORD: 1995-2001 Explorer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer
Sport Trac
MERCURY: 1997-2001 Mountaineer
This article supersedes TSB 03-05-08 to update the model year applications and to revise the
Service Procedure.
ISSUE Some Explorer/Mountaineer, Ranger and Explorer Sport/Sport Trac 4x4/AWD vehicles,
may exhibit a fluid leak from the front axle vent tube. This may be caused by fluid being thrown
toward the axle vent by the gears during vehicle operation.
ACTION Install a revised front axle cover kit. The revised cover has a baffle built in to reduce the
possibility of fluid being thrown out of the vent during vehicle operation. Refer to the following
Service Procedure.
SERVICE PROCEDURE
NOTE
DO NOT FOLLOW THE SERVICE PROCEDURE OUTLINED IN THE DANA/SPICER
INSTRUCTION SHEET INCLUDED IN THE COVER KIT. FOLLOW THE TSB SERVICE
PROCEDURE.
1. With the vehicle in NEUTRAL, raise and support the vehicle.
2. Remove the lower engine splash shield, if equipped.
3. Index-mark the front axle pinion flange and the front driveshaft.
4. Remove the driveshaft bolts and retainers. Discard the driveshaft bolts.
5. Tape the U-joint bearing caps to prevent them from falling off the U-joint.
6. Swing the driveshaft away from the axle pinion yoke and secure out of the way.
7. Remove the three (3) axle support mounting bracket bolts from the axle housing.
8. Position suitable jack beneath axle housing.
NOTE
PLACE FOLDED SHOP TOWELS OR SUITABLE SOFT MATERIAL OVER TORSION BARS TO
PROTECT THE HALFSHAFT BOOTS AND CLAMPS FROM DAMAGE.
9. Remove the two (2) bolts and nuts from the front axle support bushings. Discard the nuts.
10. Carefully lower and position the axle housing until it is resting on the torsion bars.
11. Disconnect the vent hose from the axle housing.
12. Position a drain pan under the axle housing cover. Rotate the axle housing slightly to allow
easy access to the axle cover bolts. Remove the axle housing cover and discard.
13. Clean the axle housing cover mounting surface.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Cover: > 05-6-20 > Apr > 05 >
Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 6403
14. Apply a continuous bead of silicone rubber RTV (included in the kit) to the new cover sealing
surface.
15. Install the new cover to the axle housing. Install the new vent hose and clip from the kit to the
cover (Figure 1). Tighten all bolts to 20-25 lb-ft (27-34 N.m).
16. Connect the new vent hose to the existing vent hose using the in-line connector supplied in the
kit (Figure 1).
17. Remove the old vent from the axle assembly and install the pipe plug supplied in the kit.
18. Raise the axle into position and install the axle support bushing bolts and NEW nuts. Torque
the bolts to 49 lb-ft (66 N.m).
19. Install the axle support-mounting bracket to the axle housing. Torque the bolts to 78 lb-ft (106
N.m).
20. Install the driveshaft using new bolts. Torque to 14 lb-ft (19 N.m).
21. Remove axle housing fill plug and fill with 3.25 pints (1.54 L) of Motorcraft SAE 80W-90
Premium Rear Axle Lubricant. Install fill plug.
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
050620A 1995-2001 Explorer 1.5 Hrs.
1997-2001 Mountaineer 1997-2005 Ranger 2001-2003 Explorer Sport 2001-2005 Explorer Sport
Trac: Install A Revised Axle Cover Kit
DEALER CODING
CONDITION
BASIC PART NO. CODE
4022 D1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Cover: > 05-6-20 > Apr > 05 >
Drivetrain - Front Drive Axle Vent Tube Fluid Leaks > Page 6404
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Specifications > Front
Differential Cover: Specifications Front
Differential housing cover bolt
............................................................................................................................................................
22 Nm (16 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Specifications > Front > Page 6407
Differential Cover: Specifications Rear
Torque Specifications
Differential housing cover bolts
...........................................................................................................................................................
45 Nm (33 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Specifications > Page 6408
Differential Cover: Service and Repair
Removal
1. Raise and support the vehicle.
2. Remove the differential housing cover.
1. Loosen the bolts and drain the lubricant from the rear axle housing. 2. Remove the bolts. 3.
Remove the differential housing cover.
Installation
1. CAUTION: Make sure the machined surface on the rear axle housing and the differential
housing cover are clean and free of oil before applying
the new silicone sealant. To prevent contamination, cover the inside of the rear axle prior to
cleaning the machined surface.
Clean the rear axle housing and the differential housing cover gasket mating surfaces.
2. CAUTION: Install the differential housing cover within 15 minutes of applying the silicone, or it
will be necessary to remove and reapply new
sealant.
Apply a new continuous bead of sealant to the differential housing cover. Use Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specifications ESB-M4G92-A.
3. Note: If possible, allow one hour before filling the axle with lubricant to make sure the silicone
sealant has cured.
Install the differential housing cover. 1. Install the differential housing cover. 2. Install the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Cover > Component
Information > Specifications > Page 6409
4. CAUTION: For Traction-Lok axles, first fill the rear axle with 118 ml. (4 oz.) of Ford Additive
Friction Modifier C8AZ-19B546-A or equivalent
meeting Ford specification EST-M2C118-A.
Note: In-vehicle repair refill capacities are determined by filling the rear axle to the level shown.
Fill the rear axle. For vehicles with 4.0L SOHC and 4.0L EI with Traction-Lok rear axles and 5.0L, use 2.4 liters (5.5
pints) of SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-1 9580-B or equivalent
meeting Ford specification WSL-M2C192-A, and install the filler plug
- For vehicles with 4.0L SOHC and 4.0L EI with conventional rear axles, use 2.4 liters (5.5 pints) of
SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification
WSP-M2C197-A.
5. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component
Information > Specifications > Solid Rear Axle
Fill Plug: Specifications Solid Rear Axle
Filler plug .............................................................................................................................................
.................................................... 30 Nm (22 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component
Information > Specifications > Solid Rear Axle > Page 6414
Fill Plug: Specifications Independent Rear Axle
Filler plug .............................................................................................................................................
.................................................... 34 Nm (25 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Front
Differential Oil Capacity
Refill .....................................................................................................................................................
......................................................................... 1.8 qt
Rear
Differential Oil
Capacity ...............................................................................................................................................
.......................................................... 2.4L (55 pints)
6.4 mm (0.25 in) - 14.2 mm (0.56 in) below the fill hole
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 6419
Fluid - Differential: Fluid Type Specifications
Front
Differential Fluid Type
Type .....................................................................................................................................................
..................................................................... 80W-90
Rear
Differential Fluid Type
Use SAE 80W-90 Premium Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford
specification WSP-M2C197-A for 4.0L SOHC and 4.0L EI with a conventional differential.
Use SAE 75W-140 High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting
Ford specification WSL-M2C192-A for 4.0L SOHC and 4.0L EI with a limited slip differential and
5.0L.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Specifications > Front
Pinion Bearing: Specifications
Pinion bearing preload (new pinion bearings) 15 - 30 in.lb
Pinion bearing preload (original pinion bearings)
The reading must be 0.56 Nm (5 inch lbs.) more than the
initial reading taken during disassembly
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Bearing, Differential > Component
Information > Specifications > Front > Page 6424
Pinion Bearing: Specifications Rear
Pinion bearing preload (used pinion bearings) 8 - 14 in.lb
Pinion bearing preload (new pinion bearings) 16 - 29 in.lb
Differential bearing cap bol 77 ft.lb
Independent Rear Axle
Driveshaft to Pinion Flange Bolt ..........................................................................................................
..................................................... 112 Nm. (83 lb-ft)
Differential Pinion Shaft Lock Bolt
............................................................................................................................................................
30 Nm. (22 lb-ft) * Pinion Bearing Preload (Used Bearings)
..................................................................................................................................... 0.9-1.16 Nm
(8-14 lb-in)
New Pinion Bearing .............................................................................................................................
.......................................... 1.8-3.2 Nm. (16-29 lb-in)
* With Pinion Flange Yoke Seal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle
Pinion Flange: Service and Repair Solid Rear Axle
Special Tools
Removal
1. CAUTION: Do not allow the calipers to hang from the brake hoses.
Note: Remove the rear wheels and the rear disc brake calipers to prevent brake drag during the
drive pinion bearing preload adjustment.
Remove the rear disc brake calipers.
2. Index-mark the driveshaft flange and pinion flange to maintain initial balance during installation.
3. Remove the four bolts and disconnect the d rive shaft.
- Position the driveshaft aside.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6429
4. Install a Nm (inch-pound) torque wrench on the pinion nut, and record the torque necessary to
maintain rotation of the pinion through several
revolutions.
5. CAUTION: After removing the pinion nut, discard it. Use a new nut for installation.
Use the special tool to hold the pinion flange while removing the pinion nut.
6. Index-mark the pinion flange and the drive pinion stem to maintain initial balance during
installation.
7. Using the special tool, remove the pinion flange.
Installation
1. Lubricate the pinion flange splines.
- For vehicles with 4.0L SOHC and 4.0L EI with Traction-Lok(r) differentials and 5.0L, use
Motorcraft Synthetic 75W140 Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford
specification WSL-M2C192-A.
- For vehicles with 4.0L SOHC and 4.0L EI with conventional differentials, use Thermally Stable
Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6430
2. Note: Disregard the scribe marks if installing a new pinion flange.
Align the pinion flange with the drive pinion shaft.
3. Using the special tools, install the pinion flange.
4. CAUTION: Do not under any circumstance loosen the pinion nut to reduce preload. If it is
necessary to reduce preload, install a new collapsible
spacer and pinion nut.
CAUTION: Remove the special tool when taking preload readings with the Nm (inch-pound) torque
wrench.
Use the special tool to hold the pinion flange while tightening the pinion nut. Rotate the pinion occasionally to make sure the pinion bearings seat correctly. Take frequent
pinion bearing torque preload readings by rotating the pinion with a Nm (inch-pound) torque
wrench.
- If the preload recorded prior to disassembly is lower than the specification for used bearings, then
tighten the pinion nut to specification. If the preload recorded prior to disassembly is higher than the
specification for used bearings, then tighten the pinion nut to the original reading as recorded.
- Refer to the torque specification for used pinion bearings.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6431
5. CAUTION: Be sure to align the index-marks.
Connect the driveshaft.
6. Install the rear disc brake calipers. 7. Install the rear wheel and tire assemblies. 8. Refer to the
specified axle lubricant type and fill capacity.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6432
Pinion Flange: Service and Repair Independent Rear Suspension
Drive Pinion Flange and Drive Pinion Seal
Special Tools
Material
Premium Long Life Grease XG-1-C
..........................................................................................................................................................
ESA-M1C75-B Threadlock and Sealer EOAZ-19554-AA
.............................................................................................................................. WSK-M2G351-A5
(type II) Silicone Brake Caliper Grease & Dielectric Compound
........................................................................................................................... ESE-M1C171-A
Removal
1. Position vehicle on hoist.
2. Remove the rear wheel and tire assemblies.
3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing
preload adjustment.
CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are not repairable. Use brake caliper grease for
re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6433
contamination and accelerated corrosion and wear of the caliper slide pin mechanism.
CAUTION: Do not allow the calipers to hang from the brake hoses. Support the caliper assembly
with a length of mechanic's wire.
Remove the rear disc brake caliper assembly.
1. Remove the caliper bolts. 2. Using a disc brake pad spreader, spread the disc brake pads to
allow caliper removal.
4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange for correct alignment
during installation.
Remove the four bolts.
5. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on
the driveshaft or any of its components to
disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable
tool, to disconnect the driveshaft flange from the pinion flange.
Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle flange, and
position and secure the driveshaft aside.
6 Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain
rotation of the pinion through several
revolutions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6434
7. CAUTION: Discard the nut after removing it. Install a new nut during installation.
Use the special tool to hold the pinion flange while removing the nut.
8. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation.
9. Using the special tool, remove the pinion flange.
10. Using the special tools, remove and discard the rear axle drive pinion seal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6435
Installation
1. Coat the new rear axle drive pinion seal lips with long life grease.
2. CAUTION: Installation without the correct tool can result in early seal failure.
CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the
seal and install a new seal.
Using the special tool, install the rear axle drive pinion seal.
3. Inspect the rear axle pinion flange seal journal for rust, nicks and scratches prior to installing the
flange. Polish the seal journal with fine crocus
cloth, if necessary.
4. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
5. Using the special tool, install the pinion flange.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6436
6. CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary
to reduce preload, install a new collapsible
spacer and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm (inch- pound) torque
wrench.
Use the special tool to hold the pinion flange while tightening the nut.
- Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take
frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch- pound)
torque wrench.
- If the preload recorded prior to disassembly is lower than the specification for used bearings,
tighten the nut to specification. If the preload recorded prior to disassembly is higher than the
specification for used bearings, tighten the nut to the original reading as recorded.
- Refer to torque specifications for used pinion bearings in the Specifications portion of this section.
7. NOTE: Align the index marks.
Install the four driveshaft flange to pinion flange bolts.
8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To
make sure that the yoke seats squarely on
the flange, tighten the bolts evenly in a cross pattern as shown.
CAUTION: If new bolts to retain the driveshaft to the axle flange are not available, coat the threads
of the original bolts with threadlock and sealer.
Tighten to specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Flange, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6437
9. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the
correct caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: Use the disc brake pad spreader to spread pads for reassembly. Install the rear disc brake
caliper.
10. Install the rear wheel and tire assemblies.
11. Lower the vehicle.
12. Apply the brake pedal to make sure of rear disc brake caliper piston position.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle
Pinion Gear: Service and Repair Solid Rear Axle
Special Tools
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6442
Special Tools
Special Tools
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6443
Special Tools
Removal
1. Remove the differential case.
2. CAUTION: Record the torque necessary to maintain rotation of the pinion through several
revolutions prior to removing the pinion flange
(48S1).
Remove the pinion flange.
3. Remove the rear axle drive pinion seal.
4. Remove the rear axle drive pinion shaft oil slinger.
5. Using the special tool and a soft-faced hammer, drive the pinion assembly out of the outer pinion
bearing, and remove the pinion through the rear
of the housing.
6. Remove the outer pinion bearing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6444
7. Remove and discard the collapsible spacer.
8. Using the special tool and a suitable press, remove the inner pinion bearing.
9. Note: Do not remove the pinion bearing cups from the axle housing unless the cups are
damaged.
To remove the bearing cups, tap alternately (with a brass drift of suitable length) on opposite sides
of the cup to prevent the cup from cocking in the casting.
Installation Using 205-024
1. Position the special tools and the inner and outer bearing cups in their respective axle housing
bores.
1. After placing the inner and outer bearing cups in their bores, place the special tool (inner) on the
inner pinion bearing cup. 2. Place the special tool (outer) on the outer pinion bearing cup. 3. Install
the special tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6445
2. Tighten the special tool to scat the pinion bearing cups in their bores.
Using 205-153 and 205-DOS5
3. Using the special tools, drive the outer pinion bearing cup into the axle housing.
4. Using the special tools, drive the inner pinion bearing cup into the axle housing.
Setting pinion depth
5. CAUTION: Always install new pinion bearings when installing new bearing cups.
Note: If the feeler gauge can fit between a cup and the bottom of its bore at any point around the
cup, remove and reseat the cup.
Check that the cups have seated correctly in their bores.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6446
6. Note: Apply only a light oil film on the pinion bearings before assembling the tools.
Assemble and position the special tools and pinion bearings in the axle housing. 1. Position the
Screw. 2. Position the Aligning Adapter. 3. Position the inner pinion bearing. 4. Position the Gauge
Disc. 5. Position the Gauge Block. 6. Position the outer pinion bearing. 7. Thread on the Handle.
7. Note: This step simulates pinion bearing preload.
Using a Nm (inch-pound) torque wrench, tighten the Handle to the specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6447
8. Note: Offset the Gauge Block to obtain an accurate reading.
Rotate the Gauge Block several half-lures to make sure of correct seating of the pinion bearings
and position the Gauge Block.
9. Install the special tool.
1. Position the special tool. 2. Install the bearing caps. 3. Install the four bolts.
10. Note: Use only flat, clean drive pinion bearing adjustment shims.
Note: Selection of too thick a pinion shim results in a deep tooth contact at final assembly of
integral rear axle assemblies. Do not attempt to force the pinion shim between the Gauge Block
and the Gauge Tube. A slight drag indicates correct shim selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection. Check the pinion bearing adjustment shim thickness between the Gauge Block and the Gauge
Tube.
- After determining the correct shim thickness, remove the special tools.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6448
11. Using the special tool and a suitable press, seat the pinion bearing firmly against the pinion
gear.
12. Place a new collapsible spacer on the pinion shaft against the pinion stem shoulder.
13. Install the outer pinion bearing.
14. Install the rear axle drive pinion shaft oil slinger.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6449
15. CAUTION: Installation without the correct tool can result in early seal failure.
Note: Coat the lips of the rear axle drive pinion seal with Premium Long-Life Grease XG-1-C or
equivalent meeting Ford specification ESA-M1C75-B.
Place the rear axle drive pinion seal on the special tool.
16. CAUTION: If the rear axle drive pinion seal becomes cocked during installation, remove it and
install a new one.
Place the special tool and seal in the pinion seal bore and drive the rear axle drive pinion seal into
place.
17. Install the pinion assembly (pinion, shims, inner pinion bearing, and collapsible spacer) into the
rear axle housing bore. 18. Lubricate the pinion flange splines.
- Vehicles with 4.0L SOHC and 4.0L EI with a conventional differential, use SAE 80W-90 Premium
Rear Axle Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
- Vehicles with 4.0L SOHC and 4.0L EI with Limited Slip differential and 5.0L, use SAE 75W-140
High Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
19. Note: Disregard the alignment marks if installing a new pinion flange.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6450
Align the pinion flange with the drive pinion shaft.
20. Using the special tools, install the pinion flange.
21. CAUTION: Do not under any circumstance loosen the pinion nut to reduce preload. If it is
necessary to reduce preload, install a new collapsible
spacer and pinion nut.
CAUTION: Remove the special tool when taking preload readings with the Nm (inch-pound) torque
wrench.
Use the special tool to hold the pinion flange while tightening the pinion nut. Rotate the pinion occasionally to make sure the cone and roller bearings are seating correctly.
- Install a Nm (inch-pound) torque wrench on the pinion nut.
- Rotating the pinion through several revolutions, take frequent cone and roller bearing torque
preload readings until the original recorded preload reading is obtained.
- If the original recorded preload is lower than specifications, tighten to the appropriate
specifications for used bearings. If the preload is higher than specification, tighten the nut to the
original reading as recorded. Refer to the torque specification for new pinion bearings.
22. Install differential case and the remaining components.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6451
Pinion Gear: Service and Repair Independent Rear Suspension
Drive Pinion Flange and Drive Pinion Seal
Special Tools
Material
Premium Long Life Grease XG-1-C
..........................................................................................................................................................
ESA-M1C75-B Threadlock and Sealer EOAZ-19554-AA
.............................................................................................................................. WSK-M2G351-A5
(type II) Silicone Brake Caliper Grease & Dielectric Compound
........................................................................................................................... ESE-M1C171-A
Removal
1. Position vehicle on hoist.
2. Remove the rear wheel and tire assemblies.
3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing
preload adjustment.
CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are not repairable. Use brake caliper grease for
re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6452
contamination and accelerated corrosion and wear of the caliper slide pin mechanism.
CAUTION: Do not allow the calipers to hang from the brake hoses. Support the caliper assembly
with a length of mechanic's wire.
Remove the rear disc brake caliper assembly.
1. Remove the caliper bolts. 2. Using a disc brake pad spreader, spread the disc brake pads to
allow caliper removal.
4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange for correct alignment
during installation.
Remove the four bolts.
5. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on
the driveshaft or any of its components to
disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable
tool, to disconnect the driveshaft flange from the pinion flange.
Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle flange, and
position and secure the driveshaft aside.
6 Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain
rotation of the pinion through several
revolutions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6453
7. CAUTION: Discard the nut after removing it. Install a new nut during installation.
Use the special tool to hold the pinion flange while removing the nut.
8. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation.
9. Using the special tool, remove the pinion flange.
10. Using the special tools, remove and discard the rear axle drive pinion seal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6454
Installation
1. Coat the new rear axle drive pinion seal lips with long life grease.
2. CAUTION: Installation without the correct tool can result in early seal failure.
CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the
seal and install a new seal.
Using the special tool, install the rear axle drive pinion seal.
3. Inspect the rear axle pinion flange seal journal for rust, nicks and scratches prior to installing the
flange. Polish the seal journal with fine crocus
cloth, if necessary.
4. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
5. Using the special tool, install the pinion flange.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6455
6. CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary
to reduce preload, install a new collapsible
spacer and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm (inch- pound) torque
wrench.
Use the special tool to hold the pinion flange while tightening the nut.
- Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take
frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch- pound)
torque wrench.
- If the preload recorded prior to disassembly is lower than the specification for used bearings,
tighten the nut to specification. If the preload recorded prior to disassembly is higher than the
specification for used bearings, tighten the nut to the original reading as recorded.
- Refer to torque specifications for used pinion bearings in the Specifications portion of this section.
7. NOTE: Align the index marks.
Install the four driveshaft flange to pinion flange bolts.
8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To
make sure that the yoke seats squarely on
the flange, tighten the bolts evenly in a cross pattern as shown.
CAUTION: If new bolts to retain the driveshaft to the axle flange are not available, coat the threads
of the original bolts with threadlock and sealer.
Tighten to specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component
Information > Service and Repair > Solid Rear Axle > Page 6456
9. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the
correct caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: Use the disc brake pad spreader to spread pads for reassembly. Install the rear disc brake
caliper.
10. Install the rear wheel and tire assemblies.
11. Lower the vehicle.
12. Apply the brake pedal to make sure of rear disc brake caliper piston position.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Specifications > Front
Ring Gear: Specifications Front
General Specifications
Ring gear backlash mm (inch)
....................................................................................................................................................
0.13-0.20 (0.005-0.008)
Torque Specifications
Ring gear bolt ......................................................................................................................................
.............................................. 109 Nm (80 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Specifications > Front > Page 6461
Ring Gear: Specifications Rear
Solid Rear Axle
Clearance, Tolerance and Adjustments
Maximum ring gear backface runout
............................................................................................................................................ 0.102 mm
(0.004 inch) Backlash between ring gear and pinion teeth
..............................................................................................................................................................
.................................. 0.203 mm (0.008 inch) ......................................................................................
.......................................................................................................... 0.381 mm (0.015 inch) ..............
..............................................................................................................................................................
.................... 0.305 mm (0.012 inch) ....................................................................................................
............................................................................ 0.381 mm (0.015 inch) preferred
Maximum ring gear backlash variation between teeth
.................................................................................................................. 0.102 mm (0.004 inch)
Torque Specifications
Ring gear bolts ....................................................................................................................................
.................................... 95-115 Nm (70-85 ft. lbs.)
Independent Rear Suspension
Clearance, Tolerance and Adjustments
Backlash between differential ring gear and pinion teeth
..............................................................................................................................................................
........ 0.208mm (0.008in) - 0.305mm (0.012in)
Preferred backlash ..............................................................................................................................
.................................................. 0.254mm (0.010in)
Torque Specifications
Ring gear bolts* ...................................................................................................................................
.............................................. 105 Nm (77 ft. lbs.)
* Use stud and bearing mount E)AZ-19554-BA or equivalent meeting Ford specification
WSK-M2G349-A1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Independent Rear Suspension
Ring Gear: Service and Repair Independent Rear Suspension
Differential Ring Gear Backlash
Special Tools
Material
1. Position the vehicle on a hoist.
2. Remove the drain plug from the differential housing cover and drain the differential fluid.
3. Remove the differential cover bolt from the 6 o'clock position.
4. Mount the special tool in the 6 o'clock position of the differential cover, using the differential
cover bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Independent Rear Suspension > Page 6464
5. Using the special tools, mount a suitable backlash dial indicator allowing the indicator tip to
contact the drive side of the ring gear tooth through
the drain plug hole.
6. Rotate the left halfshaft inner CV joint to move the ring gear fore and aft to measure the backlash
between the ring gear teeth and the pinion teeth.
Record the backlash.
7. Remove the dial indicator and rotate the driveshaft to turn the differential ring gear. Position the
dial indicator and record the backlash in four
places around the ring gear.
8. Proceed as follows:
- If the backlash is outside the range of 0.254 mm-0.305 mm (0.010-0.012 in), remove the
differential for further investigation.
- If the backlash is within specification, remove the tools, install the drain plug and refill the axle to
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component
Information > Service and Repair > Independent Rear Suspension > Page 6465
9. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front
Seals and Gaskets: Service and Repair Front
Special Tools
Special Tools
Removal
CAUTION: This operation disturbs the differential pinion bearing preload. Carefully reset the
preload during assembly.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle.
This can be accomplished by turning off the air suspension switch located in the rear jack storage
area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise and support the vehicle
2. Index-mark the front driveshaft and pinion flange.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6470
3. CAUTION: Do not allow the driveshaft to hang unsupported.
Disconnect the front driveshaft from the pinion flange, and position it aside. 1. Remove the bolts
and the universal joint spider retainers. 2. Disconnect the front driveshaft from the pinion flange. 3.
Position the front driveshaft aside.
4. Measure the pinion bearing preload.
- Using a Nm (inch-pound) torque wrench, measure the torque required to maintain pinion rotation.
Record the measurement.
5. Index-mark the pinion flange and the pinion stem.
6. Use the special tool to hold the pinion flange while removing the nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6471
7. CAUTION: Place a drain pan under the differential housing.
Using the special tool, remove the pinion flange.
8. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts
the bearing cone, the nut counterbore, and the
seal surface for nicks. Discard the pinion flange as necessary.
9. Using the special tool and a suitable impact slide hammer, remove the pinion seal.
10. Remove the front axle drive pinion shaft oil slinger and the differential pinion bearing. 11.
Remove and discard the collapsible spacer.
Installation
1. Verify that the splines on the pinion stem are free of burrs. If burrs are evident, remove them with
a fine crocus cloth. Work in a rotating motion to
wipe the pinion clean.
2. Clean the pinion seal bore. 3. Install a new collapsible spacer.
4. Install the original differential pinion bearing and the front axle drive pinion shaft oil slinger. 5.
Lubricate the pinion seal.
- Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification
WSP-M2C197-A.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6472
6. Using the special tool, install the pinion seal. 7. Lubricate the pinion flange splines.
- Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification
WSP-M2C197-A.
8. CAUTION: Never use a metal hammer on the pinion flange or install the flange with power tools.
If necessary, use a plastic hammer to tap on a
tight fitting Range.
Align the index marks and install the pinion flange.
9. Install the new nut hand-tight.
10. CAUTION: Do not loosen the nut to reduce preload. Install a new collapsible spacer and nut if
preload reduction is necessary.
Use the special tool to hold the pinion flange while tightening the nut to set the preload. Tighten the nut, rotating the pinion occasionally to ensure the differential pinion bearings are
seating correctly. Take frequent differential pinion bearing preload readings by rotating the pinion
with a Nm (inch-pound) torque wrench. The final reading must be 0.56 Nm (5 inch lbs.) more than
the initial reading taken during removal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6473
11. Align the index marks and position the front driveshaft.
12. Install the universal joint spider retainers and bolts. 13. Check the fluid level and, if necessary,
fill the axle to specification.
- Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification
WSP-M2C197-A.
14. Lower the vehicle. 15. If so equipped, reactivate the air suspension.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6474
Seals and Gaskets: Service and Repair Rear
Solid Rear Axle
Special Tools
Removal
1. Remove the pinion flange.
2. Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers and strike
with a hammer until the rear axle drive pinion seal
is removed.
Installation
1. Lubricate the new rear drive pinion seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1 C75-B.
2. CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the
rear axle drive pinion seal and install a new
seal.
Using the special tool, install the rear axle drive pinion seal.
3. Install the pinion flange.
Independent Rear Suspension
Drive Pinion Flange and Drive Pinion Seal
Special Tools
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6475
Material
Premium Long Life Grease XG-1-C
..........................................................................................................................................................
ESA-M1C75-B Threadlock and Sealer EOAZ-19554-AA
.............................................................................................................................. WSK-M2G351-A5
(type II) Silicone Brake Caliper Grease & Dielectric Compound
........................................................................................................................... ESE-M1C171-A
Removal
1. Position vehicle on hoist.
2. Remove the rear wheel and tire assemblies.
3. CAUTION: Remove the rear brake calipers to prevent drag during the drive pinion bearing
preload adjustment.
CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are not repairable. Use brake caliper grease for
re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in
contamination and accelerated corrosion and wear of the caliper slide pin mechanism.
CAUTION: Do not allow the calipers to hang from the brake hoses. Support the caliper assembly
with a length of mechanic's wire.
Remove the rear disc brake caliper assembly.
1. Remove the caliper bolts. 2. Using a disc brake pad spreader, spread the disc brake pads to
allow caliper removal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6476
4. CAUTION: Index-mark the driveshaft flange and rear axle pinion flange for correct alignment
during installation.
Remove the four bolts.
5. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on
the driveshaft or any of its components to
disconnect the driveshaft flange from the pinion flange. Pry only in the area shown, with a suitable
tool, to disconnect the driveshaft flange from the pinion flange.
Using a suitable tool as shown, disconnect the driveshaft flange from the rear axle flange, and
position and secure the driveshaft aside.
6 Install a Nm (inch-pound) torque wrench on the nut and record the torque necessary to maintain
rotation of the pinion through several
revolutions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6477
7. CAUTION: Discard the nut after removing it. Install a new nut during installation.
Use the special tool to hold the pinion flange while removing the nut.
8. Index-mark the pinion flange and the drive pinion stem for correct alignment during installation.
9. Using the special tool, remove the pinion flange.
10. Using the special tools, remove and discard the rear axle drive pinion seal.
Installation
1. Coat the new rear axle drive pinion seal lips with long life grease.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6478
2. CAUTION: Installation without the correct tool can result in early seal failure.
CAUTION: If the rear axle drive pinion seal becomes misaligned during installation, remove the
seal and install a new seal.
Using the special tool, install the rear axle drive pinion seal.
3. Inspect the rear axle pinion flange seal journal for rust, nicks and scratches prior to installing the
flange. Polish the seal journal with fine crocus
cloth, if necessary.
4. NOTE: Disregard the index marks if installing a new pinion flange.
Position the pinion flange.
5. Using the special tool, install the pinion flange.
6. CAUTION: Do not, under any circumstance, loosen the nut to reduce preload. If it is necessary
to reduce preload, install a new collapsible
spacer and nut.
CAUTION: Remove the special tool while taking preload readings with the Nm (inch- pound) torque
wrench.
Use the special tool to hold the pinion flange while tightening the nut.
- Rotate the pinion occasionally to make sure the differential pinion bearings seat correctly. Take
frequent differential pinion bearing preload readings by rotating the pinion with a Nm (inch- pound)
torque wrench.
- If the preload recorded prior to disassembly is lower than the specification for used bearings,
tighten the nut to specification. If the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6479
preload recorded prior to disassembly is higher than the specification for used bearings, tighten the
nut to the original reading as recorded.
- Refer to torque specifications for used pinion bearings in the Specifications portion of this section.
7. NOTE: Align the index marks.
Install the four driveshaft flange to pinion flange bolts.
8. CAUTION: The driveshaft centering socket yoke fits tightly on the rear axle pinion flange pilot. To
make sure that the yoke seats squarely on
the flange, tighten the bolts evenly in a cross pattern as shown.
CAUTION: If new bolts to retain the driveshaft to the axle flange are not available, coat the threads
of the original bolts with threadlock and sealer.
Tighten to specification.
9. CAUTION: To prevent interference with the rear disc brake caliper operation, install only the
correct caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: Use the disc brake pad spreader to spread pads for reassembly. Install the rear disc brake
caliper.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Seals and Gaskets, Differential > System
Information > Service and Repair > Front > Page 6480
10. Install the rear wheel and tire assemblies.
11. Lower the vehicle.
12. Apply the brake pedal to make sure of rear disc brake caliper piston position.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Axle Shaft Assembly, Constant Velocity Type
Axle Shaft: Specifications
Driveshaft to Driveshaft Rear Axle Pinion Flange Bolts 83 ft.lb
Front Driveshaft to Front Axle Bolts 11 - 15 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Axle Shaft Assembly, Constant Velocity Type > Page 6487
Axle Shaft: Specifications
Maximum axle shaft end play 0.03 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Page 6488
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Page 6489
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Page 6490
Axle Shaft: Description and Operation
Front Drive Halfshafts
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Page 6491
Front Drive Halfshaft and Joint Assembly
The front wheel driveshaft joints: transmit equal engine torque from the axle to both front wheels.
- use a constant velocity (CV) joint, at both the inboard and outboard ends, for operating
smoothness.
- rotate at approximately one-third the speed of a driveshaft and do not normally contribute to any
rotational vibration that may occur.
The only replaceable components of the front wheel driveshaft and joints are: Wheel driveshaft and joint boots (inboard and outboard). The replacement kit includes wheel
driveshaft and joint boots and clamps, snap rings, retainer ring and grease.
- Inboard CV joint (plunge type).
- Side shaft. Replacement includes the outboard front wheel halfshaft joint (fixed type), outboard
boot and clamps, front wheel excluder seal (assembled on the interconnecting shaft).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures
Axle Shaft: Symptom Related Diagnostic Procedures
1 of 2
2 of 2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 6494
Axle Shaft: Component Tests and General Diagnostics
Note: Constant velocity (CV) joints must not be replaced unless disassembly and inspection
reveals unusual wear.
Note: While inspecting the boots, watch for indentations ("dimples") in the boot convolutions.
Indentations must be removed.
- Inspect the boots for evidence of cracks, tears, or splits.
- Inspect the underbody for any indication of grease splatter near the boots outboard and inboard
locations. This is an indication of boot/clamp damage.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type
Axle Shaft: Service and Repair Axle Shaft Assembly, Constant Velocity Type
Bushing
Special Service Tool(s)
Removal
1. Note: Axle tube bushing removal shown, axle housing bushing is a similar procedure. Remove
the front axle assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6497
2. Position the tube bushing removal tools.
1. Position the Bushing Cup Remover/Replacer. 2. Position the Drawbolt. 3. Thread the Bushing
Remover on the Drawbolt.
3. Tighten the Drawbolt to remove the tube bushing.
Installation
1. Note: Axle tube bushing installation shown, axle housing bushing is a similar procedure.
Position the tube bushing and the tube bushing installation tools. 1. Position the tube bushing. 2.
Position the Ring Gauge. 3. Position the Bushing Collet Replacer. 4. Position the Bushing Cup
Remover/Replacer. 5. Position the Drawbolt. 6. Thread the Bushing Replacer on the Drawbolt.
2. Tighten the Drawbolt to install the tube bushing.
- Remove the tools.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6498
3. Install the front axle assembly. 4. Check the fluid level and fill the axle to specification.
- Use Motorcraft SAE 80W90 Thermally Stable 4x4 Axle Lubricant meeting Ford specification
WSP-M2C197-A.
5. Lower the vehicle. 6. If equipped with air suspension, reactivate the system by turning on the air
suspension switch.
Disassembly and Assembly
Special Tools
Disassembly
1. Remove the front wheel halfshaft.
2. CAUTION: Be careful not to damage the halfshaft boot.
Remove the two inboard boot clamps.
3. Slide the inboard halfshaft boot off the inboard CV joint housing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6499
4. Separate the CV joint from the CV joint housing.
5. Mark the shaft and the inboard CV joint to ease alignment during assembly.
6. Remove the snap ring.
7. Remove the CV joint.
8. Remove the inboard halfshaft boot from the shaft assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6500
9. Remove the two outboard boot clamps.
10. Remove the outboard halfshaft boot.
11. Note: If grease is contaminated, clean and inspect the joint for wear. Replace the outboard CV
joint and shaft assembly if worn or damaged.
Inspect for contaminated grease.
Assembly
1. Pack the outboard CV joint with grease.
1. Use Ford High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford
specification ESP-M1C207-A. 2. Spread any remaining grease from the service kit evenly inside
the outboard halfshaft boot.
2. Note: Clean the halfshaft boot mounting surfaces of access grease before positioning the
halfshaft boot into place.
Position the outboard halfshaft boot and outboard boot clamps. 1. Position the outboard halfshaft
boot.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6501
2. Position the boot clamps on the outboard halfshaft boot.
3. Note: Tighten the through-bolt until the installer is in the closed position.
Use the CV Boot Clamp Installer to install the outboard CV joint boot clamps.
4. Position the boot clamp on the halfshaft.
5. Position the inboard halfshaft boot.
6. Install the CV joint on the halfshaft.
1. Line up the marks on the halfshaft and the CV joint. 2. Install the CV joint on the halfshaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6502
7. Install the snap ring.
8. Lubricate the three CV joint needle bearings.
- Use Ford High Temp Constant Velocity Joint Grease E43Z-19590-A or equivalent meeting Ford
specification ESP-M1C207-A.
9. Fill the inboard CV joint housing with 235 grams of grease.
- Use Ford High Temp Constant Velocity Joint Grease E43Z-1 9590-A or equivalent meeting Ford
specification ESP-M1C207-A.
10. Position the CV joint housing onto the CV joint.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6503
11. Note: Remove any excess grease from the inboard halfshaft boot mating surface before
positioning into place.
Position the inboard halfshaft boot and boot clamp. 1. Position the inboard halfshaft boot into place.
2. Position the boot clamp.
12. Insert a dulled screwdriver blade to relieve built-up air pressure in the halfshaft boot.
13. Use the CV Boot Clamp Installer to install the inboard boot clamps. 14. Install the front wheel
halfshaft.
Removal and Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6504
Special Tools
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle.
This can be accomplished by turning off the air suspension switch located in the rear jack storage
area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. CAUTION: Discard the wheel hub retainer nut and washer assembly. It is a torque prevailing
design and cannot be reused.
Remove the wheel hub retainer nut and washer assembly.
4. Position the disc brake caliper aside.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6505
1. Remove the two front disc brake caliper bolts. 2. Lift the front disc brake caliper off the front disc
brake caliper anchor plate and position aside.
5. Remove the brake discs.
6. CAUTION: Do not use a hammer to separate the outboard front wheel halfshaft joint from the
hub. Damage to the outboard CV joint stub shaft
housing threads and internal components may result.
Install the special tool and separate the halfshaft from the hub. Remove the special tool.
7. Support the front suspension lower arm.
8. Remove the upper ball joint to front wheel knuckle nut and bolt.
9. Remove the outboard front wheel driveshaft and joint from the hub.
1. Rotate the front wheel knuckle. 2. Compress the outboard front wheel driveshaft and joint. 3.
Remove the outboard front wheel driveshaft and joint from the wheel hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6506
10. Using the CV Joint Puller and Impact Slide Hammer, separate the front wheel driveshaft and
joint from the front axle housing.
11. Remove the front wheel driveshaft and joint from the front axle housing.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6507
1. CAUTION: A new front axle wheel hub retaining nut and washer assembly must be installed.
CAUTION: Do not use power or impact tools to tighten the hub nut and washer assembly.
CAUTION: Do not reuse the retainer circlip. A new circlip must be installed each time the inboard
CV joint stub shaft housing is installed into the differential.
Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6508
Axle Shaft: Service and Repair Axle Shaft, Conventional Fixed/Floating
Removal
1. Raise and support the vehicle. 2. Remove the wheel and tire assembly.
3. Remove the differential housing cover.
1. Loosen the bolts and drain the lubricant from the rear axle housing. 2. Remove the bolts. 3.
Remove the differential housing cover.
4. Remove the rear brake disc.
5. CAUTION: Turning the differential case or an axle shaft with the differential pinion shaft removed
will cause the differential pinion gears to fall
out of the assembly and damage the components.
Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove
the differential pinion shaft.
6. CAUTION: Do not damage the rubber O-ring in the U-washer groove.
Remove the U-washer. 1. Push the axle shaft inboard. 2. Remove the U-washer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6509
7. Reinstall the differential pinion shaft.
1. Install the differential pinion shaft. 2. Install the differential pinion shaft lock bolt finger-tight.
8. CAUTION: Do not damage the wheel bearing oil seal.
Remove the axle shaft.
Installation
1. Lubricate the lip of the wheel bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
2. CAUTION: Turning the differential case or an axle shaft with the differential pinion shaft removed
will cause the differential pinion gears to fall
out of the assembly and damage the components.
Remove the differential pinion shaft. 1. Remove the differential pinion shaft lock bolt. 2. Remove
the differential pinion shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Axle Shaft Assembly, Constant Velocity Type > Page 6510
3. CAUTION: Do not damage the wheel bearing oil seal.
Install the axle shaft.
4. CAUTION: Do not damage the rubber O-ring in the U-washer groove.
Install the U-washer. 1. Position the U-washer on the button end of the axle shaft. 2. Pull the axle
shaft outward.
5. CAUTION: If a new pinion shaft lock bolt is unavailable, coat the threads with Threadlock and
Sealer EOAZ-19554-AA or equivalent meeting
Ford specification WSK-M2G351-A5.
Install the differential pinion shaft. 1. Align the hole in the differential pinion shaft with the differential
pinion shaft lock bolt hole. 2. Install a new differential pinion shaft lock bolt.
6. Install the rear brake disc. 7. Install the differential housing cover, and fill the rear axle housing
with the specified lubricant type and quantity. 8. Install the wheel and tire assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-11-4 > Jun > 01
> Front Axle - Squealing/Whistling Noise
Seals and Gaskets: Customer Interest Front Axle - Squealing/Whistling Noise
Article No. 01-11-4
06/11/01
^ NOISE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA - DRIVING AT
SPEEDS OF 16 - 64 KM/H (10-40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER
HALFSHAFT DUST SEALS
^ FRONT AXLE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA DRIVING AT SPEEDS OF 16 - 64 KM/H (10 - 40 MPH) - 4X4 VEHICLES ONLY - REVISED
FRONT OUTER HALFSHAFT DUST SEALS
FORD: 1998-2001 EXPLORER 2000-2001 RANGER 2001 EXPLORER SPORT TRAC,
EXPLORER SPORT
MERCURY: 1998-2001 MOUNTAINEER
This article is being republished in its entirety to update the model applications covered.
This TSB applies to 2001 Explorer Sport/Sport Trac 4X4 vehicles, 1998 - 2001
Explorer/Mountaineer 4X4 vehicles (all build dates), and 2000 - 2001 Ranger 4X4 vehicles built
after 11/1/1999 only.
ISSUE
Some 4X4 vehicles may exhibit a high-pitched "squeal" or "whistle" type noise from the front of the
vehicle at speeds from 16 to 64 km/h (10 to 40 mph). This noise may be caused by the front
halfshaft excluder (dust) seals (-3K070-) as they rotate against the inner front hubs. The noise may
be more pronounced in cold weather conditions.
ACTION
Install new front halfshaft excluder seals on each side of the vehicle. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
NOTE
THE METRIC HUB REMOVER ADAPTERS LISTED IN THE WORKSHOP MANUAL FOR THE
INSTALLATION/REMOVAL PROCEDURES ARE INCORRECT. THE CORRECT TOOL
NUMBERS ARE D93P-1175-A AND D93P-1175-B.
Perform the following for each side of the vehicle:
1. Perform the front halfshaft removal procedure per Section 205-04 of the appropriate model year
Workshop Manual.
2. Restrain the halfshaft assembly by the outboard (wheel end) joint outer race. Clamp with a vise
on the exposed metal surface only. The CV joint should be in an upright position (splined end up).
Be careful not to damage the boot or boot clamp.
3. Remove the old seal by prying it off the shaft.
4. Clean the outer race of the CV joint of any remaining foreign matter.
5. Install the new Front Halfshaft Excluder Seal (YL2Z-3K070-AA) by pressing it onto the outer race
of the outboard CV joint by hand or with an appropriate hand tool. All seal markings will be facing
the bell of the joint (away from the stem).
NOTE
BE CAREFUL TO ONLY PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL. START
THE SEAL ON THE HALFSHAFT BY HAND, AND THEN PRESS ON THE EXPOSED STEEL
PORTION OF THE SEAL IN 20 DEGREE INCREMENTS AROUND THE SEAL
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 01-11-4 > Jun > 01
> Front Axle - Squealing/Whistling Noise > Page 6519
UNTIL IT IS FULLY SEATED AND PARALLEL TO THE CV JOINT FACE. BE CAREFUL TO
AVOID DAMAGING THE RUBBER PORTION OF THE SEAL.
6. Spread an approximately 3 mm (1/8") thick bead of High-Temperature Wheel Bearing Grease
(E8TZ-19590-A) onto the new seal lips.
7. Clean the inner surface of the knuckle (-3K185-/-3K186-). This is the metal surface the seals will
ride against.
8. Perform the halfshaft installation procedure per Section 205-04 of the appropriate Workshop
Manual.
9. Verity that the noise is no longer present.
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-4-11 WARRANTY STATUS: Eligible
Under The Provision Of Bumper To Bumper Warranty Coverage.
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 509000, 597997, 702000, 702100, 703200, 703300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-11-4
> Jun > 01 > Front Axle - Squealing/Whistling Noise
Seals and Gaskets: All Technical Service Bulletins Front Axle - Squealing/Whistling Noise
Article No. 01-11-4
06/11/01
^ NOISE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA - DRIVING AT
SPEEDS OF 16 - 64 KM/H (10-40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER
HALFSHAFT DUST SEALS
^ FRONT AXLE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA DRIVING AT SPEEDS OF 16 - 64 KM/H (10 - 40 MPH) - 4X4 VEHICLES ONLY - REVISED
FRONT OUTER HALFSHAFT DUST SEALS
FORD: 1998-2001 EXPLORER 2000-2001 RANGER 2001 EXPLORER SPORT TRAC,
EXPLORER SPORT
MERCURY: 1998-2001 MOUNTAINEER
This article is being republished in its entirety to update the model applications covered.
This TSB applies to 2001 Explorer Sport/Sport Trac 4X4 vehicles, 1998 - 2001
Explorer/Mountaineer 4X4 vehicles (all build dates), and 2000 - 2001 Ranger 4X4 vehicles built
after 11/1/1999 only.
ISSUE
Some 4X4 vehicles may exhibit a high-pitched "squeal" or "whistle" type noise from the front of the
vehicle at speeds from 16 to 64 km/h (10 to 40 mph). This noise may be caused by the front
halfshaft excluder (dust) seals (-3K070-) as they rotate against the inner front hubs. The noise may
be more pronounced in cold weather conditions.
ACTION
Install new front halfshaft excluder seals on each side of the vehicle. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
NOTE
THE METRIC HUB REMOVER ADAPTERS LISTED IN THE WORKSHOP MANUAL FOR THE
INSTALLATION/REMOVAL PROCEDURES ARE INCORRECT. THE CORRECT TOOL
NUMBERS ARE D93P-1175-A AND D93P-1175-B.
Perform the following for each side of the vehicle:
1. Perform the front halfshaft removal procedure per Section 205-04 of the appropriate model year
Workshop Manual.
2. Restrain the halfshaft assembly by the outboard (wheel end) joint outer race. Clamp with a vise
on the exposed metal surface only. The CV joint should be in an upright position (splined end up).
Be careful not to damage the boot or boot clamp.
3. Remove the old seal by prying it off the shaft.
4. Clean the outer race of the CV joint of any remaining foreign matter.
5. Install the new Front Halfshaft Excluder Seal (YL2Z-3K070-AA) by pressing it onto the outer race
of the outboard CV joint by hand or with an appropriate hand tool. All seal markings will be facing
the bell of the joint (away from the stem).
NOTE
BE CAREFUL TO ONLY PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL. START
THE SEAL ON THE HALFSHAFT BY HAND, AND THEN PRESS ON THE EXPOSED STEEL
PORTION OF THE SEAL IN 20 DEGREE INCREMENTS AROUND THE SEAL
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-11-4
> Jun > 01 > Front Axle - Squealing/Whistling Noise > Page 6525
UNTIL IT IS FULLY SEATED AND PARALLEL TO THE CV JOINT FACE. BE CAREFUL TO
AVOID DAMAGING THE RUBBER PORTION OF THE SEAL.
6. Spread an approximately 3 mm (1/8") thick bead of High-Temperature Wheel Bearing Grease
(E8TZ-19590-A) onto the new seal lips.
7. Clean the inner surface of the knuckle (-3K185-/-3K186-). This is the metal surface the seals will
ride against.
8. Perform the halfshaft installation procedure per Section 205-04 of the appropriate Workshop
Manual.
9. Verity that the noise is no longer present.
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-4-11 WARRANTY STATUS: Eligible
Under The Provision Of Bumper To Bumper Warranty Coverage.
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 509000, 597997, 702000, 702100, 703200, 703300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
6526
Seals and Gaskets: By Symptom
Technical Service Bulletin # 01-11-4 Date: 010611
Front Axle - Squealing/Whistling Noise
Article No. 01-11-4
06/11/01
^ NOISE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA - DRIVING AT
SPEEDS OF 16 - 64 KM/H (10-40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER
HALFSHAFT DUST SEALS
^ FRONT AXLE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA DRIVING AT SPEEDS OF 16 - 64 KM/H (10 - 40 MPH) - 4X4 VEHICLES ONLY - REVISED
FRONT OUTER HALFSHAFT DUST SEALS
FORD: 1998-2001 EXPLORER 2000-2001 RANGER 2001 EXPLORER SPORT TRAC,
EXPLORER SPORT
MERCURY: 1998-2001 MOUNTAINEER
This article is being republished in its entirety to update the model applications covered.
This TSB applies to 2001 Explorer Sport/Sport Trac 4X4 vehicles, 1998 - 2001
Explorer/Mountaineer 4X4 vehicles (all build dates), and 2000 - 2001 Ranger 4X4 vehicles built
after 11/1/1999 only.
ISSUE
Some 4X4 vehicles may exhibit a high-pitched "squeal" or "whistle" type noise from the front of the
vehicle at speeds from 16 to 64 km/h (10 to 40 mph). This noise may be caused by the front
halfshaft excluder (dust) seals (-3K070-) as they rotate against the inner front hubs. The noise may
be more pronounced in cold weather conditions.
ACTION
Install new front halfshaft excluder seals on each side of the vehicle. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
NOTE
THE METRIC HUB REMOVER ADAPTERS LISTED IN THE WORKSHOP MANUAL FOR THE
INSTALLATION/REMOVAL PROCEDURES ARE INCORRECT. THE CORRECT TOOL
NUMBERS ARE D93P-1175-A AND D93P-1175-B.
Perform the following for each side of the vehicle:
1. Perform the front halfshaft removal procedure per Section 205-04 of the appropriate model year
Workshop Manual.
2. Restrain the halfshaft assembly by the outboard (wheel end) joint outer race. Clamp with a vise
on the exposed metal surface only. The CV joint should be in an upright position (splined end up).
Be careful not to damage the boot or boot clamp.
3. Remove the old seal by prying it off the shaft.
4. Clean the outer race of the CV joint of any remaining foreign matter.
5. Install the new Front Halfshaft Excluder Seal (YL2Z-3K070-AA) by pressing it onto the outer race
of the outboard CV joint by hand or with an appropriate hand tool. All seal markings will be facing
the bell of the joint (away from the stem).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
6527
NOTE
BE CAREFUL TO ONLY PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL. START
THE SEAL ON THE HALFSHAFT BY HAND, AND THEN PRESS ON THE EXPOSED STEEL
PORTION OF THE SEAL IN 20 DEGREE INCREMENTS AROUND THE SEAL UNTIL IT IS
FULLY SEATED AND PARALLEL TO THE CV JOINT FACE. BE CAREFUL TO AVOID
DAMAGING THE RUBBER PORTION OF THE SEAL.
6. Spread an approximately 3 mm (1/8") thick bead of High-Temperature Wheel Bearing Grease
(E8TZ-19590-A) onto the new seal lips.
7. Clean the inner surface of the knuckle (-3K185-/-3K186-). This is the metal surface the seals will
ride against.
8. Perform the halfshaft installation procedure per Section 205-04 of the appropriate Workshop
Manual.
9. Verity that the noise is no longer present.
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-4-11 WARRANTY STATUS: Eligible
Under The Provision Of Bumper To Bumper Warranty Coverage.
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 509000, 597997, 702000, 702100, 703200, 703300
Technical Service Bulletin # 01-11-4 Date: 010611
Front Axle - Squealing/Whistling Noise
Article No. 01-11-4
06/11/01
^ NOISE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA - DRIVING AT
SPEEDS OF 16 - 64 KM/H (10-40 MPH) - 4X4 VEHICLES ONLY - REVISED FRONT OUTER
HALFSHAFT DUST SEALS
^ FRONT AXLE - "SQUEALING" OR "WHISTLING" NOISE FROM FRONT AXLE AREA DRIVING AT SPEEDS OF 16 - 64 KM/H (10 - 40 MPH) - 4X4 VEHICLES ONLY - REVISED
FRONT OUTER HALFSHAFT DUST SEALS
FORD: 1998-2001 EXPLORER 2000-2001 RANGER 2001 EXPLORER SPORT TRAC,
EXPLORER SPORT
MERCURY:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
6528
1998-2001 MOUNTAINEER
This article is being republished in its entirety to update the model applications covered.
This TSB applies to 2001 Explorer Sport/Sport Trac 4X4 vehicles, 1998 - 2001
Explorer/Mountaineer 4X4 vehicles (all build dates), and 2000 - 2001 Ranger 4X4 vehicles built
after 11/1/1999 only.
ISSUE
Some 4X4 vehicles may exhibit a high-pitched "squeal" or "whistle" type noise from the front of the
vehicle at speeds from 16 to 64 km/h (10 to 40 mph). This noise may be caused by the front
halfshaft excluder (dust) seals (-3K070-) as they rotate against the inner front hubs. The noise may
be more pronounced in cold weather conditions.
ACTION
Install new front halfshaft excluder seals on each side of the vehicle. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
NOTE
THE METRIC HUB REMOVER ADAPTERS LISTED IN THE WORKSHOP MANUAL FOR THE
INSTALLATION/REMOVAL PROCEDURES ARE INCORRECT. THE CORRECT TOOL
NUMBERS ARE D93P-1175-A AND D93P-1175-B.
Perform the following for each side of the vehicle:
1. Perform the front halfshaft removal procedure per Section 205-04 of the appropriate model year
Workshop Manual.
2. Restrain the halfshaft assembly by the outboard (wheel end) joint outer race. Clamp with a vise
on the exposed metal surface only. The CV joint should be in an upright position (splined end up).
Be careful not to damage the boot or boot clamp.
3. Remove the old seal by prying it off the shaft.
4. Clean the outer race of the CV joint of any remaining foreign matter.
5. Install the new Front Halfshaft Excluder Seal (YL2Z-3K070-AA) by pressing it onto the outer race
of the outboard CV joint by hand or with an appropriate hand tool. All seal markings will be facing
the bell of the joint (away from the stem).
NOTE
BE CAREFUL TO ONLY PRESS ON THE EXPOSED STEEL PORTION OF THE SEAL. START
THE SEAL ON THE HALFSHAFT BY HAND, AND THEN PRESS ON THE EXPOSED STEEL
PORTION OF THE SEAL IN 20 DEGREE INCREMENTS AROUND THE SEAL UNTIL IT IS
FULLY SEATED AND PARALLEL TO THE CV JOINT FACE. BE CAREFUL TO AVOID
DAMAGING THE RUBBER PORTION OF THE SEAL.
6. Spread an approximately 3 mm (1/8") thick bead of High-Temperature Wheel Bearing Grease
(E8TZ-19590-A) onto the new seal lips.
7. Clean the inner surface of the knuckle (-3K185-/-3K186-). This is the metal surface the seals will
ride against.
8. Perform the halfshaft installation procedure per Section 205-04 of the appropriate Workshop
Manual.
9. Verity that the noise is no longer present.
Parts Block
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-4-11 WARRANTY STATUS: Eligible
Under The Provision Of Bumper To Bumper Warranty Coverage.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page
6529
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 509000, 597997, 702000, 702100, 703200, 703300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Page 6530
Seals and Gaskets: Service and Repair
Special Tools
Special Tools
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive
Axles > System Information > Technical Service Bulletins > Page 6531
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Specifications
Wheel Bearing: Specifications
Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
Lubricate the lip of the new wheel bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Testing and Inspection > Wheel Bearing Check
Wheel Bearing: Testing and Inspection Wheel Bearing Check
1. Raise and support the vehicle.
^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can
be the cause of a strain problem.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH
CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
2. Spin the tire by hand to check the wheel bearings for roughness.
NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow
free movement of the tire and wheel assembly.
3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Testing and Inspection > Wheel Bearing Check > Page 6537
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Testing and Inspection > Wheel Bearing Check > Page 6538
Wheel Bearing: Testing and Inspection Wheel Bearing Inspection
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise the vehicle until the tire is off the floor.
2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of
the following actions.
^ On 4x2 vehicles, adjust the front wheel bearings.
^ On 4x4 vehicles, install a new wheel hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Solid Rear Axle
Wheel Bearing: Service and Repair Solid Rear Axle
Special Tools
Special Tools
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Solid Rear Axle > Page 6541
Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component
Information > Service and Repair > Solid Rear Axle > Page 6542
Wheel Bearing: Service and Repair Independent Rear Suspension
Wheel Bearing
Removal And Installation
1. Remove the wheel knuckle.
2. CAUTION: Make sure that the press adapter outside diameter is slightly smaller than the hub
outside diameter or damage to the knuckle will
result.
Using a suitable press, remove the hub from the bearing.
- Discard the hub.
3. NOTE: The retainer ring is tapered and must be installed flat side down.
Remove the retainer ring.
- Discard the retainer ring.
4. Using a suitable press, remove the bearing from the wheel knuckle.
- Discard the bearing.
5. CAUTION: The hub and bearing cannot be reused after disassembly.
To install. reverse the removal Procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
Wheel Hub Nut 157-213 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Specifications
Drive/Propeller Shaft: Specifications
Rear driveshaft screws 70-95 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Diagrams > Driveshaft
Drive/Propeller Shaft: Diagrams Driveshaft
Driveshaft-Rear, 4X2
1 of 3
2 of 3
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Diagrams > Driveshaft > Page 6553
3 of 3
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Diagrams > Driveshaft > Page 6554
Drive/Propeller Shaft: Diagrams Universal Joints
1 of 2
2 of 2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Description and Operation > Universal Joints
Drive/Propeller Shaft: Description and Operation Universal Joints
The universal joints are: lubed-for-life design and require no lubrication.
- equipped with nylon thrust washers, located at each base of the bearing cup, which control end
play, position the needle bearing and improve grease movement.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Description and Operation > Universal Joints > Page 6557
Drive/Propeller Shaft: Description and Operation Driveshaft
Note: Whenever the vehicle is raised on a hoist, inspect the universal joint slip yoke boot for rips or
holes. Replace if required.
Note: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and universal
joints to prevent application of any undercoating material.
Note: The constant velocity (CV) joint on the front driveshaft is not serviceable.
The front driveshaft is connected to the transfer case and the front drive axle by a driveshaft flange
yoke.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft-Front
Drive/Propeller Shaft: Service and Repair Driveshaft-Front
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the rear jack storage area. Failure to do so can result in unexpected
inflation or deflation of the air springs, which can result in shifting of the vehicle during these
operations.
1. With the vehicle in neutral, raise and support the vehicle.
2. Index-mark the front axle pinion flange to the front driveshaft. 3. Remove the transfer case skid
plate.
4. Index-mark the transfer case pinion flange to the front driveshaft.
5. Remove the front driveshaft CV joint-to-transfer case bolts and washers.
6. Remove the front driveshaft-to-front axle bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6560
7. Note: Always disconnect the front driveshaft from the transfer case first.
Remove the front driveshaft.
Installation
1. Note: Install new front driveshaft CV joint-to-transfer case bolts and washers and new front
driveshaft-to-front axle bolts and straps. If new bolts
are not available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA
or equivalent meeting Ford specification WSK-M2G351-A5.
Note: Always install the front driveshaft at the front axle first.
To install, follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6561
Drive/Propeller Shaft: Service and Repair Driveshaft-Rear, 4X2
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle.
This can be accomplished by turning off the air suspension switch located in the rear jack storage
area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
With the vehicle in neutral, raise and support the vehicle.
2. Index-mark the driveshaft to driveshaft rear axle pinion flange.
3. Note: Index-mark the driveshaft slip yoke to the transmission output shaft.
Remove the driveshaft. 1. Remove and discard the four bolts, and disconnect the driveshaft. 2.
Lower the driveshaft, and slide the driveshaft rearward out of the transmission.
- Plug the extension housing to prevent fluid loss.
Installation
1. Note: Install new rear driveshaft-to-driveshaft rear axle pinion flange bolts. If new bolts are not
available, coat the threads of the original bolts
with Threadlock and Sealer EOAZ-19554-AA or equivalent meeting Ford specification
WSK-M2G351-A5.
To install, follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6562
Drive/Propeller Shaft: Service and Repair Driveshaft-Rear, 4X4
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension vehicle.
This can be accomplished by turning off the air suspension switch located in the rear jack storage
area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can
result in shifting of the vehicle during these operations.
With the vehicle in neutral, raise and support the vehicle.
2. Index-mark the driveshaft yoke to the transfer case pinion flange.
3. Index-mark the driveshaft to driveshaft rear axle pinion flange.
4. Remove the four rear bolts, and disconnect the rear driveshaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Drive/Propeller
Shaft > Component Information > Service and Repair > Driveshaft-Front > Page 6563
5. Separate the driveshaft from the transfer case.
1. Remove the four bolts. 2. Carefully remove the driveshaft.
Installation
1. Note: Install new rear driveshaft-to-driveshaft rear axle pinion flange bolts and driveshaft flange
yoke-to-transfer case bolts. If new bolts are not
available, coat the threads of the original bolts with Threadlock and Sealer EOAZ-19554-AA or
equivalent meeting Ford specification WSK-M2G351-A5.
To install, follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Service and Repair
Slip Yoke: Service and Repair
Special Tools
Disassembly
1. Remove the driveshaft.
2. CAUTION: Do not clamp the driveshaft in the jaws of a vise or similar holding fixture.
Remove the driveshaft slip yoke boot. 1. Index-mark the driveshaft to the driveshaft slip yoke. 2.
With the rear driveshaft on a bench, cut and discard the driveshaft slip yoke boot clamps. 3.
Separate the driveshaft slip yoke from the splined stub shaft on the driveshaft, and remove the
driveshaft slip yoke boot.
- Inspect the driveshaft slip yoke boot for damage and replace if required.
3. Inspect the lubricant for contamination. If contaminated, inspect the stub shaft and driveshaft slip
yoke for wear. Replace the driveshaft as needed.
Assembly
1. Slide the small opening end of the driveshaft slip yoke boot on the splined stub shaft as far as it
will travel. 2. Install the small driveshaft slip yoke boot clamp and use Keystone Clamp Pliers to
crimp the small driveshaft slip yoke boot clamp.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Slip Yoke >
Component Information > Service and Repair > Page 6567
3. Install the driveshaft slip yoke.
1. Lubricate the stub shaft splines, and pull the driveshaft slip yoke boot towards the driveshaft.
- Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification
ESA-M1C75-B.
2. Fill the driveshaft slip yoke boot with approximately 10 grams of lubricant.
- Use Premium Long-Life Grease XG-1-C or -K or equivalent meeting Ford specification
ESA-M1C75-B.
3. Position the large driveshaft slip yoke boot clamp. 4. Align the index marks made during
disassembly, and install the driveshaft slip yoke.
4. Install the large driveshaft slip yoke boot clamp.
1. Remove any excess grease from the differential slip yoke boot and driveshaft slip yoke surfaces.
2. Position the driveshaft slip yoke boot over the driveshaft slip yoke boot groove. 3. Position the
driveshaft slip yoke to specification from the driveshaft weld to the end of the slip yoke splines. 4.
Bleed air from the driveshaft slip yoke boot. 5. Use Keystone Clamp Pliers to crimp the large
driveshaft slip yoke boot clamp.
5. Install the driveshaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Specifications
Universal Joint: Specifications
Universal joint spider retainer bolt 14 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke
Universal Joint: Service and Repair Single Cardan, Flange Yoke
Special Tools
Disassembly
1. Remove the driveshaft.
2. CAUTION: Do not clamp the driveshaft in a vise or similar holding fixture.
Place the driveshaft on a suitable workbench, being careful not to damage the tube.
3. Note: If components are not marked and installed correctly, driveline imbalance can occur.
Index-mark the positions of the driveshaft components.
4. Clamp the U joint tool in a vise.
5. Remove all four of the snap rings.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6573
6. Remove the driveshaft flange yoke.
1. Position the driveshaft flange yoke in the U-joint tool. 2. Press out a bearing cup. 3. Remove the
driveshaft flange yoke. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the
driveshaft flange yoke.
7. Remove the spider.
1. Reposition the driveshaft in the U-joint tool. 2. Press out the bearing cup. 3. Rotate the
driveshaft. 4. Press on the spider to remove the remaining bearing cup. 5. Remove the spider.
8. Clean the yoke area at the end of the driveshaft.
Assembly
1. Note: Universal joint kits are to be installed as complete assemblies only. Do not mix
components from other U-joint kits.
Install the spider. 1. Start a new bearing cup into the driveshaft yoke.
- Check the needle bearings for correct positioning.
2. Position the new spider in the driveshaft yoke. 3. Position the driveshaft in the U joint tool. 4.
Press the bearing cup to just below the snap ring groove.
- Repeat for the other bearing cup.
2. Inspect the driveshaft flange yoke. Install new if necessary.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6574
3. Install the driveshaft flange yoke.
1. Start a new bearing cup into the driveshaft flange yoke.
- Check the needle bearings for correct positioning.
2. Position the driveshaft flange yoke. 3. Position the driveshaft in the U-joint tool. 4. Press the
bearing cup to just below the snap ring groove.
- Repeat for the other bearing cup.
4. Note: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If
difficulty is encountered with the yellow snap
rings, install the black snap rings.
Remove the driveshaft from the U-joint tool, and install the four snap rings.
5. Note: Do not strike the bearings.
Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer.
6. Install the driveshaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6575
Universal Joint: Service and Repair Universal Joint -Single Cardan
Special Tools
Disassembly
1. CAUTION: Under no circumstances is the driveshaft assembly to be clamped in the jaws of a
vise or similar holding fixture. Denting or
localizing fracture can result, causing driveshaft failure during vehicle operation.
Place the driveshaft on a suitable workbench. Be careful not to damage the tube.
2. Note: If components are not marked and therefore installed incorrectly, driveline imbalance can
occur.
Index-mark the driveshaft components.
3. Clamp U-joint tool in a vise.
4. Remove all four of the snap rings.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6576
5. Note: If necessary, use a pair of pliers to remove a bearing cup if it cannot be pressed out all the
way.
Remove the driveshaft slip-yoke. 1. Position the driveshaft slip-yoke in the U-joint tool. 2. Press out
a bearing cup. 3. Rotate the driveshaft slip-yoke. 4. Press on the spider to remove the remaining
bearing cup. 5. Remove the driveshaft slip-yoke.
6. Repeat Step 5 to remove the remaining bearing cups and spider from the driveshaft. 7. Clean
the yoke area at each end of the driveshaft.
Assembly
1. Note: Universal Joint Service Kits are to be installed as complete assemblies only. Do not mix
components from other U-Joint Kits.
Install the bearing cup. 1. Start a new bearing cup into the driveshaft yoke. Check the needle bearings for correct positioning.
2. Position the new spider in the driveshaft yoke. 3. Using the U-joint tool, press the bearing cup to
just below the snap ring groove.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Universal Joint,
Drive/Propeller Shaft > Component Information > Service and Repair > Single Cardan, Flange Yoke > Page 6577
2. Note: Use the yellow snap rings supplied in the kit to assemble the universal joint (U-joint). If
difficulty is encountered with the yellow snap
rings, install the black snap rings.
Remove the driveshaft from the U joint tool, and install the snap ring.
3. Repeat Steps 1 and 2 to install the opposite side of the driveshaft yoke. 4. Inspect the driveshaft
slip-yoke. Install a new yoke, if necessary. 5. Repeat Steps 1 and 2 to install the remaining new
bearing cups, spider, driveshaft slip-yoke, and the snap rings.
6. Note: Do not strike the bearings.
Check the U-joints for freedom of movement. If binding, strike the yoke with a brass or plastic hammer.
7. Install the driveshaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
Flywheel Bolts Stage 1 13 Nm (10 ft.lbs.)
Special bolts are used for flywheel installation; do not
use standard bolts.
Stage 2 71 Nm (52 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page
6581
Flex Plate: Service and Repair
Removal
1. Remove the transmission.
2. Remove the flywheel. 3. Clean and inspect the flywheel.
Installation
1. Note: Special bolts are used for flywheel installation; do not use standard bolts.
Install the flywheel. Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten to 13 Nm (10 ft. lbs.).
- Stage 2: Tighten 71 Nm (52 ft. lbs.).
2. Install the transmission.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Specifications
Flywheel: Specifications
Flywheel Bolts 75 - 85 ft.lb
Flywheel Runout 0.005 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair >
Dowels - Flywheel
Flywheel: Service and Repair Dowels - Flywheel
Removal
1. Note: Take care not to damage the flywheel dowel holes or surface areas around the flywheel
dowel during removal.
Remove the flywheel dowels by using a drift pin where the flywheel dowel is installed in an open
hole, and locking pliers where the flywheel dowel is installed in a blind hole.
Installation
1. Note: Care should be taken to drive the flywheel dowel squarely into place until fully seated and
to not damage surrounding surface areas.
Install all flywheel dowels by driving them into place using a brass or plastic mallet.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair >
Dowels - Flywheel > Page 6587
Flywheel: Service and Repair Flywheel - Removal and Installation
Special Tools
Removal
1. Remove the clutch disc and pressure plate.
2. CAUTION: Two bolts should be loosened but left in to prevent the flywheel from falling.
Remove six of eight bolts. Loosen the two remaining bolts but leave in place.
3. Press the flywheel off the crankshaft.
- Install the two bolts in the threaded holes in the flywheel and remove flywheel.
4. Remove the bolts remaining in the crankshaft. 5. Remove the flywheel.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Flywheel > Component Information > Service and Repair >
Dowels - Flywheel > Page 6588
1. Position the flywheel onto the crankshaft and install the flywheel-to-crankshaft bolts.
- Apply Threadlock and Sealer EOAZ-1955AA or equivalent meeting Ford specification
WSK-M2G315-A5 (Type II) to bolt threads.
2. Install the disc and pressure plate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Overdrive Indicator Lamp > Component Information > Locations > Page 6594
Overdrive Indicator Lamp: Description and Operation
Overdrive (O/D) Off
The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function
indicator will also flash off and on if a transmission
malfunction is detected.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Shift Indicator > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Shift Indicator > Component Information > Locations > Page 6598
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D)
position.
- Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents
counterclockwise (D) position).
3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever.
4. Center the pointer in the middle of the (D) position.
- Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and
compare with the transmission settings.
- Readjust if necessary.
7. Install the upper instrument panel steering column cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - A/T > Transmission Mode Indicator - A/T > Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and
Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Bell Housing, M/T >
Component Information > Service and Repair
Bell Housing: Service and Repair
Removal
1. Note: Take care not to damage the flywheel housing-to-block dowel holes or surface areas
around the flywheel housing-to-block dowel hole
during removal.
Remove the flywheel housing-to-block dowels using a drift pin where the flywheel housing-to-block
dowel is installed in an open hole, and locking pliers where the flywheel housing-to-block dowel is
installed in a blind hole.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component
Information > Specifications
Case: Specifications
Case Cover Bolts 12 - 16 ft.lb
Case Plug 30 - 43 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T >
Component Information > Specifications
Countershaft: Specifications
Countershaft Locknut 94 - 144 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Drain Plug, M/T > Component
Information > Specifications
Drain Plug: Specifications
Drain Plug 30 - 43 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Specifications
Extension Housing: Specifications
Torque Specifications
Extension Housing Bolts
...........................................................................................................................................................
32-46 Nm (24-33 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Specifications > Page 6622
Extension Housing: Service and Repair
Special Tools
Removal
1. If equipped, turn the air suspension switch off. 2. Disconnect the battery ground cable. 3. Raise
and support the vehicle. 4. On 4WD vehicles, remove the transfer case. 5. Drain the transmission
fluid.
6. Note: To maintain initial driveshaft balance, mark the driveshaft centering socket yoke and rear
axle universal joint flange so they may be
installed in their original positions.
Mark the driveshaft centering socket yoke and rear axle universal joint flange.
7. Remove and support the rear driveshaft.
1. Remove the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Specifications > Page 6623
2. Remove the rear driveshaft.
8. Use the (A) Hi-Lift Jack to support the (B) transmission.
- Secure the (B) transmission with the (C) strap.
9. Remove the nuts.
10. Remove the crossmember.
1. Remove the six bolts (three each side). 2. Remove the crossmember.
11. Remove the (RH) transmission mount bolt.
1. Remove the bolt. 2. Reposition the exhaust mounting bracket.
12. Lower the transmission to access extension housing bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Specifications > Page 6624
13. Use the Seal Remover to remove the extension housing seal.
14. Remove the extension housing.
1. Remove the bolts. 2. Remove the extension housing.
Installation
1. Note: The extension housing must be installed within four minutes after applying silicone.
Apply a small bead of Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford specification
ESB-M4G92-A to the surface of the case.
2. Install the extension housing.
1. Position the extension housing. 2. Install the bolts.
3. Use Extension Housing Seal Replacer to install the extension housing seal. 4. Raise and
position the transmission.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Specifications > Page 6625
5. Install the (RH) transmission mount bolt.
1. Position the exhaust bracket. 2. Install the bolt.
6. install the crossmember.
1. Position the crossmember. 2. Install the six bolts and nuts (three each side).
7. Remove the Hi-Lift Jack.
8. Install the nuts.
9. Note: To maintain initial driveshaft balance, align marks on the rear driveshaft centering socket
yoke and rear axle universal joint flange made
during removal.
Install the rear driveshaft. 1. Position the rear driveshaft. 2. Install the four bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Extension Housing, M/T >
Component Information > Specifications > Page 6626
10. Fill the (A) transmission with MERCON Multi-Purpose Automatic Transmission Fluid XT-2-QDX
or DDX or equivalent meeting Ford MERCON
specification until it reaches the bottom of the (B) fill port and install the (C) case plug.
11. Lower the vehicle. 12. Connect the battery ground cable. 13. If equipped with air suspension,
reactivate the system by turning on the air suspension switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fill Plug, M/T > Component
Information > Specifications
Fill Plug: Specifications
Fill Plug 30 - 43 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information
Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information
TSB 06-26-1
01/08/07
MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME
MANUAL TRANSMISSIONS
FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco
1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super
Duty 2001-2003 Explorer Sport Trac, Explorer Sport
LINCOLN: 2001-2002 Lincoln LS
MERCURY: 1984-1995 Cougar 1987-1999 Tracer
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the
service fluid for manual transmissions originally requiring MERCON(R).
ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can
now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual
usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic
Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue
until remaining inventory has been depleted.
SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6634
Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper
fluid application on current and past model manual transmissions refer to the fluid usage chart.
(Figure 1)
WARNING
FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR
OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT
(XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS
RECOMMENDING THAT PARTICULAR FLUID.
USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 6635
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications > Capacity Specifications
Fluid - M/T: Capacity Specifications
Manual Transmission
Capacity ...............................................................................................................................................
................................................................... 2.7 Quarts Note: Approximate refill. Service refill
capacity is determined by filling the transmission to the bottom of the filler hole with the vehicle on a
level surface.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component
Information > Specifications > Capacity Specifications > Page 6638
Fluid - M/T: Fluid Type Specifications
Manual Transmission Fluid ..................................................................................................................
............................................................. Mercon ATF
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Flywheel Gear, M/T >
Component Information > Service and Repair
Flywheel Gear: Service and Repair
Removal
WARNING: This procedure should be performed only by a properly equipped and experienced
acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety
goggles when handling the heated flywheel ring gear.
1. Remove the flywheel.
2. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating
crayons to prevent over heating.
CAUTION: Tap the flywheel ring gear evenly to prevent binding.
Remove the flywheel ring gear from the flywheel. Evenly heat the flywheel ring gear and use a brass drift to drive the flywheel ring gear off the
flywheel.
Installation
WARNING: This procedure should be performed only by a properly equipped and experienced
acetylene torch operator. To avoid personal injury, use tongs or wear welding gloves and safety
goggles when handling the heated flywheel ring gear.
1. CAUTION: Do not heat the flywheel ring gear beyond 278°C (500°F). Use heat indicating
crayons to prevent over heating.
CAUTION: Keep the torch moving to prevent hot spots.
Evenly heat the flywheel ring gear.
2. Install the flywheel ring gear.
- The bevel on the flywheel ring gear must face the rear of the flywheel.
- Use a brass drift.
3. Install the flywheel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer
Ring, M/T > Component Information > Specifications
Synchronizer Ring: Specifications
Synchronizer Blocking Ring to Gear mm (in)
................................................................................................................................................. 1.5
(0.059)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T >
Component Information > Specifications
Output Shaft: Specifications
Output Shaft Maximum Runout mm (in)
.......................................................................................................................................................
0.05 (0.002) Output Shaft Locknut
........................................................................................................................................................
216-274 Nm (160-202 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Idler Gear >
Component Information > Specifications
Reverse Idler Gear: Specifications
Reverse Idler Gear End Play
........................................................................................................................................ 0.1-0.2 mm
(0.0039-0.0078 inch) Reverse Idler Shaft Bolt
...........................................................................................................................................................
79-117 Nm (58-86 ft. lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Specifications > Page 6656
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission > Page 6659
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6660
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page
6663
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page
6664
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T >
Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page
6665
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component
Information > Specifications
Shift Fork: Specifications
Shift Fork to Synchronizer Sleeve 0.031 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Specifications
Shifter M/T: Specifications
Gearshift Lever Bolt 20 - 29 ft.lb
Inner Gearshift Lever Boot Bolts 89 - 123 in.lb
Outer Gearshift Lever Boot Screws 45 - 79 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Specifications > Page 6672
Shifter M/T: Service and Repair
Removal
1. Remove the gearshift lever.
1. Lift the outer gearshift lever boot. 2. Remove the bolt. 3. Remove the gearshift lever.
2. Remove the inner gearshift lever boot.
1. Remove the four screws. 2. Remove the inner gearshift lever boot.
Installation
1. Install the inner gearshift lever boot.
1. Position the inner gearshift lever boot. 2. Install the screws.
2. Install the gearshift lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shifter M/T > Component
Information > Specifications > Page 6673
1. Position the gearshift lever. 2. Install the bolt.
3. Install the screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Mount, M/T >
Component Information > Specifications
Transmission Mount: Specifications
Transmission Mount Bolts 64 - 81 ft.lb
Transmission Mount Nuts 64 - 81 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Specifications > Page 6680
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Diagrams > 4R70W Transmission
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Diagrams > 4R70W Transmission > Page 6683
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Diagrams > Page 6684
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6687
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6688
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Transmission Speed Sensor,
M/T > Component Information > Service and Repair > Transfer Case - Automatic Shift > Page 6689
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair
Control Module: Service and Repair
Removal
1. Remove the transmission control switch (TCS).
1. Remove the TCS cover. 2. Remove the TCS.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions
Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6701
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6702
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6703
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6704
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6705
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6706
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6707
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6708
Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6709
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6710
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6711
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6712
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6713
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6714
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Diagram Information
and Instructions > Page 6715
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6716
Control Module: Description and Operation
The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between
three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any
speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake
depressed and the transmission must be in NEUTRAL.
The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect
the speed of the front and rear driveshafts. This input is used by the generic electronic module
(GEM) primarily to control A4WD operation.
The throttle position output signal is provided to the GEM from the powertrain control module
(PCM). This signal is used by the GEM in controlling the A4WD clutch.
The shift motor sense plate an integral part of the electric shift motor informs the GEM to the
position of the transfer case.
The digital TR sensors are located on the LH side of the transmission; these sensors inform the
GEM when the transmission is in the neutral position.
The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam
which moves the mode fork and range fork within the transfer case between the HIGH range
(A4WD 4HIGH) and LOW range positions.
The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts
the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes.
The solid state clutch relay is used to activate the A4WD clutch within the transfer case.
System Function
Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM
varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under
cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of
time the clutch is turned on) which allows for the slight difference between the front and rear
driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the
following conditions the GEM will increase the duty cycle in order to prevent or control slip:
^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position).
Feature inputs:
^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch
(manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^
Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate
position inputs A B C D.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential
when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4
shift motor relay outputs.
Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and
outputs needed by the GEM to execute a change between any of these modes. Feature inputs:
^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD
mode switch.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential
when relay is off).
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Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6717
^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated).
When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h
(3 mph) the brake is applied and the transmission is in NEUTRAL.
Feature inputs:
^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^
Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage
when brake is depressed open circuit when not activated). ^ Digital transmission range sensor
(ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input
(manual transmission only).
Feature outputs:
^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit
when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is
on baftery potential when relay is off).
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Modules - Transfer Case > Control Module, Transfer Case > Component Information > Diagrams > Page 6718
Control Module: Service and Repair
AUTOMATIC FOUR WHEEL DRIVE (A4WD)
Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives
Throttle Position Information From the PCM Only.
Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage may result.
Depower the supplemental restraint system (SRS).
2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact
Disc
3. Remove the center instrument panel finish panel.
1. Remove the screws. 2. Remove the center instrument panel finish panel.
^ Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the
GEM/CTM.
1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy.
2. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions
Four Wheel Drive Selector Relay: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6724
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6725
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6726
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6727
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6728
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6729
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6730
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6731
Four Wheel Drive Selector Relay: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6732
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6733
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6734
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6735
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6736
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6737
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - Transfer Case > Four Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information
and Instructions > Page 6738
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Description and Operation
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6747
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6748
Digital Transmission Range Sensor: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6749
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6750
6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission Position Switch/Sensor, A/T] > Component
Information > Specifications > Page 6751
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Specifications > Page 6755
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6758
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6759
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6760
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6761
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6762
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6763
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6764
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6765
Transmission Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6766
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6767
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6768
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6769
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6770
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6771
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6772
Transmission Speed Sensor: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 6773
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 6774
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6777
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6778
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6779
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6785
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6786
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6787
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6788
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6789
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6790
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6791
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6792
Transmission Temperature Sensor/Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6793
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6794
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6795
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6796
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6797
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6798
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 6799
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Page 6800
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Specifications > Page 6805
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > 4R70W Transmission >
Page 6808
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Diagrams > Page 6809
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6812
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6813
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - M/T > Transmission Speed Sensor, M/T > Component Information > Service and Repair > Transfer Case Automatic Shift > Page 6814
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions
Four Wheel Drive Selector Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6821
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6822
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6823
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6824
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6825
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6826
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6827
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6828
Four Wheel Drive Selector Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6829
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6830
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6831
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6832
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6833
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Diagram
Information and Instructions > Page 6834
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 6835
Four Wheel Drive Selector Switch: Description and Operation
Switch, Push Button 4x4 Mode
The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select
the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the
instrument cluster push button, will illuminate only when the 4x4 Low position is engaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component Information > Diagrams > Page 6836
Four Wheel Drive Selector Switch: Service and Repair
Removal and Installation
1. Remove and reposition the center instrument panel finish panel.
2. Disconnect the 4x4 mode switch electrical connector.
3. Remove the 4x4 mode switch.
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Specifications
Transfer Case Actuator: Specifications
Transfer case shift motor bolts
..............................................................................................................................................................
10 Nm (89 inch lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions
Transfer Case Actuator: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6844
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6845
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6846
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6847
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6848
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6849
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6850
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6851
Transfer Case Actuator: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6852
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6853
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6854
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6855
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6856
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6857
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 6858
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Page 6859
Transfer Case Actuator: Service and Repair
Removal and Installation
1. With the vehicle in the NEUTRAL position, raise and support the vehicle.
2. Remove the heat shield.
3. Disconnect the electrical connector.
4. Remove the coil wire from the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Page 6860
1. Remove the connector interlock. 2. Remove the coil wire pin.
- Use the proper electrical connector pin remover.
5. Remove the rear output shaft speed sensor.
- Carefully remove the sensor from the transfer case.
6. Remove the four bolts and the transfer case shift motor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Actuators and Solenoids - Transfer Case >
Transfer Case Actuator > Component Information > Diagrams > Page 6861
7. Remove the front output shaft speed sensor.
- Carefully remove the sensor from transfer case.
8. NOTE: Make sure the motor mounting surfaces are clean.
Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case.
9. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6867
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6868
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6869
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6870
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6871
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6872
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6873
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6874
Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6875
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6876
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6877
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6878
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6879
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6880
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 6881
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Page 6882
Control Module: Description and Operation
The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between
three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any
speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake
depressed and the transmission must be in NEUTRAL.
The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect
the speed of the front and rear driveshafts. This input is used by the generic electronic module
(GEM) primarily to control A4WD operation.
The throttle position output signal is provided to the GEM from the powertrain control module
(PCM). This signal is used by the GEM in controlling the A4WD clutch.
The shift motor sense plate an integral part of the electric shift motor informs the GEM to the
position of the transfer case.
The digital TR sensors are located on the LH side of the transmission; these sensors inform the
GEM when the transmission is in the neutral position.
The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam
which moves the mode fork and range fork within the transfer case between the HIGH range
(A4WD 4HIGH) and LOW range positions.
The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts
the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes.
The solid state clutch relay is used to activate the A4WD clutch within the transfer case.
System Function
Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM
varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under
cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of
time the clutch is turned on) which allows for the slight difference between the front and rear
driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the
following conditions the GEM will increase the duty cycle in order to prevent or control slip:
^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position).
Feature inputs:
^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch
(manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^
Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate
position inputs A B C D.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential
when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4
shift motor relay outputs.
Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and
outputs needed by the GEM to execute a change between any of these modes. Feature inputs:
^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD
mode switch.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential
when relay is off).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Page 6883
^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated).
When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h
(3 mph) the brake is applied and the transmission is in NEUTRAL.
Feature inputs:
^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^
Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage
when brake is depressed open circuit when not activated). ^ Digital transmission range sensor
(ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input
(manual transmission only).
Feature outputs:
^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit
when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is
on baftery potential when relay is off).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Page 6884
Control Module: Service and Repair
AUTOMATIC FOUR WHEEL DRIVE (A4WD)
Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives
Throttle Position Information From the PCM Only.
Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage may result.
Depower the supplemental restraint system (SRS).
2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact
Disc
3. Remove the center instrument panel finish panel.
1. Remove the screws. 2. Remove the center instrument panel finish panel.
^ Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the
GEM/CTM.
1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy.
2. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube
Fluid Leaks
Fluid - Transfer Case: Customer Interest Front Axle - Vent Tube Fluid Leaks
Article No. 01-8-6
4/30/01
^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4
OR AWD
^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH
4X4 OR AWD
FORD: 1995-2001 EXPLORER 1997-2001 RANGER
MERCURY: 1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model applications and model
years.
ISSUE
Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer
Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by
the gears during vehicle operation.
ACTION
Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover
has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle
operation. Refer to the Instruction Sheet included in the kit and the following text for details.
The Cover Kit (F6TZ-4033-BA) includes the following:
^ One (1) Cover One (1) Hose
^ One (1) Hose Connector One (1) Vent Plug One (1) Clip
^ One (1) Sealant
^ One (1) Instruction Sheet
NOTE
SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND
BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
010806A Install Axle Cover kit 1.7 Hrs.
DEALER CODING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > Customer Interest for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube
Fluid Leaks > Page 6893
CONDITION
BASIC PART NO. CODE
4022 D1
OASIS CODES: 509000, 510000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle Vent Tube Fluid Leaks
Fluid - Transfer Case: All Technical Service Bulletins Front Axle - Vent Tube Fluid Leaks
Article No. 01-8-6
4/30/01
^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4
OR AWD
^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH
4X4 OR AWD
FORD: 1995-2001 EXPLORER 1997-2001 RANGER
MERCURY: 1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model applications and model
years.
ISSUE
Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer
Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by
the gears during vehicle operation.
ACTION
Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover
has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle
operation. Refer to the Instruction Sheet included in the kit and the following text for details.
The Cover Kit (F6TZ-4033-BA) includes the following:
^ One (1) Cover One (1) Hose
^ One (1) Hose Connector One (1) Vent Plug One (1) Clip
^ One (1) Sealant
^ One (1) Instruction Sheet
NOTE
SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND
BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
010806A Install Axle Cover kit 1.7 Hrs.
DEALER CODING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Fluid - Transfer Case: > 01-8-6 > Apr > 01 > Front Axle Vent Tube Fluid Leaks > Page 6899
CONDITION
BASIC PART NO. CODE
4022 D1
OASIS CODES: 509000, 510000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Transfer Case Capacity .......................................................................................................................
.................................................................... 1.5 Quarts
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component Information
> Specifications > Capacity Specifications > Page 6902
Fluid - Transfer Case: Fluid Type Specifications
Transfer Case Fluid
Type .....................................................................................................................................................
............................................................. Mercon ATF
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Indicator Lamp > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions
Four Wheel Drive Selector Relay: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6911
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6912
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6913
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6914
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6915
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6916
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6917
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6918
Four Wheel Drive Selector Relay: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6919
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6920
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6921
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6922
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6923
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6924
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 6925
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions
Four Wheel Drive Selector Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6931
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6932
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6933
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6934
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6935
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6936
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6937
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6938
Four Wheel Drive Selector Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6939
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6940
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6941
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6942
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6943
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 6944
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Page 6945
Four Wheel Drive Selector Switch: Description and Operation
Switch, Push Button 4x4 Mode
The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select
the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the
instrument cluster push button, will illuminate only when the 4x4 Low position is engaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Page 6946
Four Wheel Drive Selector Switch: Service and Repair
Removal and Installation
1. Remove and reposition the center instrument panel finish panel.
2. Disconnect the 4x4 mode switch electrical connector.
3. Remove the 4x4 mode switch.
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Lamps and Indicators - Transfer Case > Four
Wheel Drive Indicator Lamp > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6957
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6958
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6959
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6960
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6961
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6962
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6963
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6964
Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6965
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6966
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6967
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6968
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6969
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6970
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Diagram Information and Instructions > Page 6971
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Page 6972
Control Module: Description and Operation
The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between
three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any
speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake
depressed and the transmission must be in NEUTRAL.
The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect
the speed of the front and rear driveshafts. This input is used by the generic electronic module
(GEM) primarily to control A4WD operation.
The throttle position output signal is provided to the GEM from the powertrain control module
(PCM). This signal is used by the GEM in controlling the A4WD clutch.
The shift motor sense plate an integral part of the electric shift motor informs the GEM to the
position of the transfer case.
The digital TR sensors are located on the LH side of the transmission; these sensors inform the
GEM when the transmission is in the neutral position.
The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam
which moves the mode fork and range fork within the transfer case between the HIGH range
(A4WD 4HIGH) and LOW range positions.
The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts
the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes.
The solid state clutch relay is used to activate the A4WD clutch within the transfer case.
System Function
Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM
varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under
cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of
time the clutch is turned on) which allows for the slight difference between the front and rear
driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the
following conditions the GEM will increase the duty cycle in order to prevent or control slip:
^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position).
Feature inputs:
^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch
(manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^
Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate
position inputs A B C D.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential
when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4
shift motor relay outputs.
Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and
outputs needed by the GEM to execute a change between any of these modes. Feature inputs:
^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD
mode switch.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential
when relay is off).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Page 6973
^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated).
When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h
(3 mph) the brake is applied and the transmission is in NEUTRAL.
Feature inputs:
^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^
Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage
when brake is depressed open circuit when not activated). ^ Digital transmission range sensor
(ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input
(manual transmission only).
Feature outputs:
^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit
when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is
on baftery potential when relay is off).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Control
Module, Transfer Case > Component Information > Diagrams > Page 6974
Control Module: Service and Repair
AUTOMATIC FOUR WHEEL DRIVE (A4WD)
Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives
Throttle Position Information From the PCM Only.
Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage may result.
Depower the supplemental restraint system (SRS).
2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact
Disc
3. Remove the center instrument panel finish panel.
1. Remove the screws. 2. Remove the center instrument panel finish panel.
^ Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the
GEM/CTM.
1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy.
2. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions
Four Wheel Drive Selector Relay: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6980
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6981
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6982
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6983
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6984
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6985
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6986
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6987
Four Wheel Drive Selector Relay: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6988
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6989
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6990
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6991
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6992
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6993
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Relays and Modules - Transfer Case > Four
Wheel Drive Selector Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 6994
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair
Seals and Gaskets: Service and Repair
Removal
WARNING: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during
these operations.
1. With the transmission in neutral, raise and support the vehicle.
2. Index-mark the rear output flange and the driveshaft yoke.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair > Page 6998
3. Remove the four bolls.
4. Separate the driveshaft from the output flange, and position the driveshaft aside.
5. Index-mark the rear output flange to the rear output shaft.
6. Use the special tool to hold the rear output flange while removing the nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Seals and Gaskets, Transfer Case > System
Information > Service and Repair > Page 6999
7. Remove the rear output flange.
1. Remove the output shaft yoke washer. 2. Remove the oil seal. 3. Remove the rear output flange.
8. Using the special tools, remove the oil seal.
Installation
1. To install, reverse the removal procedure.
- Use the special tool to install the oil seal.
- Check, and if necessary, fill the transfer case to the specified level with the specified fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions
Four Wheel Drive Selector Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7006
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7007
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7008
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7009
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7010
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7011
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7012
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7013
Four Wheel Drive Selector Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7014
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7015
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7016
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7017
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7018
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7019
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Page 7020
Four Wheel Drive Selector Switch: Description and Operation
Switch, Push Button 4x4 Mode
The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select
the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the
instrument cluster push button, will illuminate only when the 4x4 Low position is engaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Sensors and Switches - Transfer Case > Four
Wheel Drive Selector Switch > Component Information > Diagrams > Page 7021
Four Wheel Drive Selector Switch: Service and Repair
Removal and Installation
1. Remove and reposition the center instrument panel finish panel.
2. Disconnect the 4x4 mode switch electrical connector.
3. Remove the 4x4 mode switch.
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Specifications
Transfer Case Actuator: Specifications
Transfer case shift motor bolts
..............................................................................................................................................................
10 Nm (89 inch lbs.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions
Transfer Case Actuator: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7027
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7028
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7029
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7030
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7031
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7032
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7033
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7034
Transfer Case Actuator: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7035
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7036
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7037
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7038
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7039
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7040
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Diagram Information and Instructions > Page 7041
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Page 7042
Transfer Case Actuator: Service and Repair
Removal and Installation
1. With the vehicle in the NEUTRAL position, raise and support the vehicle.
2. Remove the heat shield.
3. Disconnect the electrical connector.
4. Remove the coil wire from the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Page 7043
1. Remove the connector interlock. 2. Remove the coil wire pin.
- Use the proper electrical connector pin remover.
5. Remove the rear output shaft speed sensor.
- Carefully remove the sensor from the transfer case.
6. Remove the four bolts and the transfer case shift motor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Actuator > Component
Information > Diagrams > Page 7044
7. Remove the front output shaft speed sensor.
- Carefully remove the sensor from transfer case.
8. NOTE: Make sure the motor mounting surfaces are clean.
Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case.
9. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information >
Technical Service Bulletins > Customer Interest for Transfer Case Cover: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube
Fluid Leaks
Transfer Case Cover: Customer Interest Front Axle - Vent Tube Fluid Leaks
Article No. 01-8-6
4/30/01
^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4
OR AWD
^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH
4X4 OR AWD
FORD: 1995-2001 EXPLORER 1997-2001 RANGER
MERCURY: 1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model applications and model
years.
ISSUE
Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer
Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by
the gears during vehicle operation.
ACTION
Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover
has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle
operation. Refer to the Instruction Sheet included in the kit and the following text for details.
The Cover Kit (F6TZ-4033-BA) includes the following:
^ One (1) Cover One (1) Hose
^ One (1) Hose Connector One (1) Vent Plug One (1) Clip
^ One (1) Sealant
^ One (1) Instruction Sheet
NOTE
SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND
BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
010806A Install Axle Cover kit 1.7 Hrs.
DEALER CODING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information >
Technical Service Bulletins > Customer Interest for Transfer Case Cover: > 01-8-6 > Apr > 01 > Front Axle - Vent Tube
Fluid Leaks > Page 7053
CONDITION
BASIC PART NO. CODE
4022 D1
OASIS CODES: 509000, 510000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Cover: > 01-8-6 > Apr > 01 > Front Axle Vent Tube Fluid Leaks
Transfer Case Cover: All Technical Service Bulletins Front Axle - Vent Tube Fluid Leaks
Article No. 01-8-6
4/30/01
^ AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH 4X4
OR AWD
^ LEAK - AXLE - FRONT AXLE LEAKS FLUID FROM VENT TUBE - VEHICLES EQUIPPED WITH
4X4 OR AWD
FORD: 1995-2001 EXPLORER 1997-2001 RANGER
MERCURY: 1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model applications and model
years.
ISSUE
Fluid may leak out of the front axle vent tube on some Explorer/Mountaineer, Ranger and Explorer
Sport and Sport Trac vehicles. This may be caused by fluid being thrown toward the axle vent by
the gears during vehicle operation.
ACTION
Replace the axle cover and install the Axle Cover Kit (F6TZ-4033-BA). The revised housing cover
has a baffle built in to reduce the possibility of fluid being thrown out of the vent during vehicle
operation. Refer to the Instruction Sheet included in the kit and the following text for details.
The Cover Kit (F6TZ-4033-BA) includes the following:
^ One (1) Cover One (1) Hose
^ One (1) Hose Connector One (1) Vent Plug One (1) Clip
^ One (1) Sealant
^ One (1) Instruction Sheet
NOTE
SINCE TORQUE PREVAILING FASTENERS MUST NOT BE REUSED, ALL LISTED NUTS AND
BOLTS MUST BE ORDERED AND BE ON-HAND FOR EACH AXLE KIT INSTALLED.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-26 WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
010806A Install Axle Cover kit 1.7 Hrs.
DEALER CODING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transfer Case > Transfer Case Cover > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transfer Case Cover: > 01-8-6 > Apr > 01 > Front Axle Vent Tube Fluid Leaks > Page 7059
CONDITION
BASIC PART NO. CODE
4022 D1
OASIS CODES: 509000, 510000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations
Pressure Regulating Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 7066
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 7067
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Locations > Page 7068
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Pressure Regulating Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7071
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7072
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7073
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7074
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7075
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7076
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7077
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7078
Pressure Regulating Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7079
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7080
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7081
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7082
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7083
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7084
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7085
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 7086
Pressure Regulating Solenoid: Description and Operation
Electronic Pressure Control (EPC) Solenoid
The electronic pressure control (EPC) solenoid is a variable force style (VFS) solenoid. The VFS
type solenoid is an electro-hydraulic actuator combining a solenoid and a regulating valve.
The powertrain control module varies the current to the EPC solenoid.
This action causes the solenoid to regulate transmission line pressure and line modulator pressure.
This is done by producing resisting forces to the main regulator and line modulator circuits. These
two solenoids control clutch application pressures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 7087
Pressure Regulating Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 7088
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 7089
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component
Information > Diagrams > Page 7090
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications
Shift Interlock Solenoid: Specifications
Shift Lock Actuator Bolts 62.5-98 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information >
Specifications > Page 7094
Shift Interlock Solenoid: Service and Repair
Removal
1. Remove the steering column assembly.
2. Remove the insert plate and shift lock actuator.
1. Remove the bolts. 2. Remove the insert plate and shift lock actuator.
3. Note: The shift lock actuator clip is an assembly aid for the assembly plant and does not need to
be replaced.
Remove the insert plate from the shift lock actuator. Remove and discard the shift lock actuator clip.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
Shift Solenoid: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Page 7098
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Page 7099
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Page 7100
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions
Shift Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7103
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7104
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7105
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7106
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7107
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7108
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7109
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7110
Shift Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7111
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7112
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams >
Diagram Information and Instructions > Page 7113
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Diagram Information and Instructions > Page 7114
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Diagram Information and Instructions > Page 7115
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Diagram Information and Instructions > Page 7116
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Diagram Information and Instructions > Page 7117
Diagram 29-4
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Page 7118
Shift Solenoid: Description and Operation
Shift Solenoids A, B, C, and D
Four On/Off shift solenoids allow the powertrain control module to control shift scheduling.
- The solenoids are two-way, normally open style.
- The shift solenoids (SSA, SSB, SSC, and SSD) provide gear selection by controlling the
pressures of the shift valves.
- SSD is also used to apply and release the coast clutch.
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Page 7119
Shift Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Page 7120
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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Page 7121
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
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Page 7122
2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
Information > Specifications
Torque Converter Clutch Solenoid: Specifications
TCC Solenoid Bolt 80-97 in.lb
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Information > Specifications > Page 7126
Torque Converter Clutch Solenoid: Locations
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Information > Specifications > Page 7128
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Information > Specifications > Page 7129
SSA, SSC solenoids
1. TCC solenoid
2. SSB, SSD solenoids
3. EPC solenoid
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Information > Diagrams > Diagram Information and Instructions
Torque Converter Clutch Solenoid: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Information > Diagrams > Diagram Information and Instructions > Page 7132
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Information > Diagrams > Diagram Information and Instructions > Page 7134
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Information > Diagrams > Diagram Information and Instructions > Page 7137
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Information > Diagrams > Diagram Information and Instructions > Page 7139
Torque Converter Clutch Solenoid: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Information > Diagrams > Diagram Information and Instructions > Page 7144
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Diagram 29-4
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Information > Diagrams > Page 7147
Torque Converter Clutch Solenoid: Description and Operation
Torque Converter Clutch (TCC) Solenoid
The torque converter clutch (TCC) solenoid is used to control the apply and release of the TCC.
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Information > Diagrams > Page 7148
Torque Converter Clutch Solenoid: Service and Repair
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Note: Transmission servo heat shield needs to be unclipped from the fluid pan rail and
positioned out of the way for fluid pan removal.
Loosen the nut and position the heat shield out of the way.
4. Place a drain pan under the transmission fluid pan. 5. Drain the transmission fluid.
6. Remove the transmission fluid filter.
1. Remove the transmission fluid filter screw. 2. Remove the transmission fluid filter.
7. Note: Main control assembly does not need to be removed for solenoid service.
Remove wire loom guide and protector. Carefully lift up on wire loom guide and protector and disengage the retaining pins from the
solenoid clamps.
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Information > Diagrams > Page 7149
8. Disconnect the appropriate solenoid electrical connector.
1. Disconnect shift solenoids electrical connectors. 2. Disconnect the torque converter clutch (TCC)
solenoid electrical connector. 3. Disconnect the electronic pressure control (EPC) solenoid
electrical connector.
9. CAUTION: The TCC solenoid and converter modulator valve may pop out of its bore. This may
damage the solenoid or converter modulator
valve.
CAUTION: Shift solenoid (SSC) may pop out of its bore. This may damage the solenoid.
Remove the shift solenoids. 1. Remove the wire harness. 2. Remove the solenoid clamp screws. 3.
Remove the solenoid clamp. 4. Remove the appropriate solenoid(s).
Installation
1. Install the new solenoid(s).
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Information > Diagrams > Page 7150
2. CAUTION: The solenoid clamp must be installed in the TCC and EPC solenoid grooves, shift
solenoid pockets and the No. 204 plug.
Install the solenoid clamp. 1. Position the solenoid clamp on the main control valve body. 2. Install
the solenoid clamp screws.
3. Connect the six solenoid electrical connectors.
1. Connect shift solenoid SSA, SSB, SSC, SSD electrical connectors. 2. Connect the torque
converter clutch (TCC) solenoid electrical connector. 3. Connect the electrical pressure control
(EPC) solenoid electrical connector.
4. CAUTION: Excessive pressure may break the retaining pins.
Install the main control valve body wire loom. Align the retaining pins to the holes in the solenoid clamps and gently press in the main control
valve body wire loom guide and protector.
5. Install the transmission fluid filter.
1. Install the transmission fluid filter.
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2. Install the transmission fluid filter screw.
6. Install the transmission fluid pan.
1. Position a new transmission fluid pan gasket on the transmission fluid pan. 2. Align and install
the transmission fluid pan.
- Loosely install the transmission fluid pan screws.
7. Tighten the transmission fluid pan screws.
8. Position the servo heat shield over the servos and clip it to the pan rail. 9. Lower the vehicle.
10. Connect the battery ground cable. 11. Fill the transmission to the proper fluid level and check
for proper transmission operation.
- Use MERCON V Automatic Transmission Fluid XT-5-QM or equivalent meeting MERCON (R) V
specification.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Specifications
Transfer Case Actuator: Specifications
Transfer case shift motor bolts
..............................................................................................................................................................
10 Nm (89 inch lbs.)
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> Diagrams > Diagram Information and Instructions
Transfer Case Actuator: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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> Diagrams > Diagram Information and Instructions > Page 7158
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 7159
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 7160
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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> Diagrams > Diagram Information and Instructions > Page 7162
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> Diagrams > Diagram Information and Instructions > Page 7163
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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> Diagrams > Diagram Information and Instructions > Page 7165
Transfer Case Actuator: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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> Diagrams > Diagram Information and Instructions > Page 7167
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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> Diagrams > Diagram Information and Instructions > Page 7169
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> Diagrams > Diagram Information and Instructions > Page 7170
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 7171
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - Transfer Case > Transfer Case Actuator > Component Information
> Diagrams > Diagram Information and Instructions > Page 7172
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> Diagrams > Page 7173
Transfer Case Actuator: Service and Repair
Removal and Installation
1. With the vehicle in the NEUTRAL position, raise and support the vehicle.
2. Remove the heat shield.
3. Disconnect the electrical connector.
4. Remove the coil wire from the electrical connector.
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> Diagrams > Page 7174
1. Remove the connector interlock. 2. Remove the coil wire pin.
- Use the proper electrical connector pin remover.
5. Remove the rear output shaft speed sensor.
- Carefully remove the sensor from the transfer case.
6. Remove the four bolts and the transfer case shift motor.
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> Diagrams > Page 7175
7. Remove the front output shaft speed sensor.
- Carefully remove the sensor from transfer case.
8. NOTE: Make sure the motor mounting surfaces are clean.
Apply a 3-mm (1/8-inch) bead of sealant to the motor mounting surface on the case.
9. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information >
Locations
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Overdrive Indicator Lamp > Component Information >
Locations > Page 7181
Overdrive Indicator Lamp: Description and Operation
Overdrive (O/D) Off
The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function
indicator will also flash off and on if a transmission
malfunction is detected.
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7185
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D)
position.
- Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents
counterclockwise (D) position).
3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever.
4. Center the pointer in the middle of the (D) position.
- Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and
compare with the transmission settings.
- Readjust if necessary.
7. Install the upper instrument panel steering column cover.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Transmission Mode Indicator - A/T > Component Information >
Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - Transfer Case > Four Wheel Drive Indicator Lamp > Component
Information > Locations
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair
Control Module: Service and Repair
Removal
1. Remove the transmission control switch (TCS).
1. Remove the TCS cover. 2. Remove the TCS.
Installation
1. Follow the removal procedure in reverse order.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Locations
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Information > Diagrams > Diagram Information and Instructions
Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Information > Diagrams > Diagram Information and Instructions > Page 7204
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 7205
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Information > Diagrams > Diagram Information and Instructions > Page 7206
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Information > Diagrams > Diagram Information and Instructions > Page 7207
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Information > Diagrams > Diagram Information and Instructions > Page 7208
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Information > Diagrams > Diagram Information and Instructions > Page 7209
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Information > Diagrams > Diagram Information and Instructions > Page 7210
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Information > Diagrams > Diagram Information and Instructions > Page 7211
Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Information > Diagrams > Diagram Information and Instructions > Page 7212
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Information > Diagrams > Diagram Information and Instructions > Page 7213
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 7214
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 7215
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 7216
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 7217
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Diagram Information and Instructions > Page 7218
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Page 7219
Control Module: Description and Operation
The A4WD system is an electrostatic shift 4x4 system that allows the operator to choose between
three different 4x4 modes. The operator can switch between A4WD and 4WD HIGH modes at any
speed. To engage or disengage LOW range the vehicle speed must be less than 5 km/h the brake
depressed and the transmission must be in NEUTRAL.
The front/rear driveshaft speed sensors (Hall effect) are mounted to the transfer case and detect
the speed of the front and rear driveshafts. This input is used by the generic electronic module
(GEM) primarily to control A4WD operation.
The throttle position output signal is provided to the GEM from the powertrain control module
(PCM). This signal is used by the GEM in controlling the A4WD clutch.
The shift motor sense plate an integral part of the electric shift motor informs the GEM to the
position of the transfer case.
The digital TR sensors are located on the LH side of the transmission; these sensors inform the
GEM when the transmission is in the neutral position.
The electric shift motor is mounted externally at the rear of the transfer case. It drives a rotary cam
which moves the mode fork and range fork within the transfer case between the HIGH range
(A4WD 4HIGH) and LOW range positions.
The 4x4 shift motor uses a module containing two relays which under the control of the GEM shifts
the transfer case shift motor between HIGH range (A4VVD 4HIGH) and 4LOW modes.
The solid state clutch relay is used to activate the A4WD clutch within the transfer case.
System Function
Hall effect sensor monitors input and output shaft speed. In the A4WD (C-Trac) system the GEM
varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and under
cruising conditions the GEM activates the transfer case clutch a minimum duty cycle (percentage of
time the clutch is turned on) which allows for the slight difference between the front and rear
driveshafts which normally occurs when negotiating a corner on dry pavement. Under any of the
following conditions the GEM will increase the duty cycle in order to prevent or control slip:
^ Slip is detected (by using the Hall Effect Sensors) ^ Heavy acceleration (throttle position).
Feature inputs:
^ Brake ON/OFF switch. ^ 4WD mode switch. ^ Digital transmission range sensor. ^ Clutch switch
(manual transmission vehicles only). ^ Vehicle speed signal (transmitted from the ABS module). ^
Front/rear driveshaft speed sensors. ^ Throttle position information from the PCM. ^ Contact plate
position inputs A B C D.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal: grounded when relay is on battery potential
when relay is off). ^ A4WD indicator (ground when activated open circuit when deactivated). ^ 4x4
shift motor relay outputs.
Shifts between A4WD and 4x4 HIGH can be made at any speed. Listed below are the inputs and
outputs needed by the GEM to execute a change between any of these modes. Feature inputs:
^ Front/rear driveshaft speed sensor. ^ Vehicle speed signal. ^ Throttle position information. ^ 4WD
mode switch.
Feature outputs:
^ Solid state clutch relay (pulse width modulated signal; grounded when relay is on battery potential
when relay is off).
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Page 7220
^ 4x4 HIGH cluster indicator (ground when activated open circuit when deactivated).
When shifting into or out of LOW range the GEM requires that the vehicle speed is less than 5km/h
(3 mph) the brake is applied and the transmission is in NEUTRAL.
Feature inputs:
^ Throttle position information. ^ 4WD mode switch. ^ Contact plate position inputs A B C D. ^
Vehicle speed signal (transmitted from ABS module). ^ Brake ON/OFF switch input (battery voltage
when brake is depressed open circuit when not activated). ^ Digital transmission range sensor
(ground when transmission is in NEUTRAL open circuit otherwise). ^ Start/clutch depressed input
(manual transmission only).
Feature outputs:
^ 4x4 shift motor relay outputs. ^ 4LOW cluster indicators (ground when activated open circuit
when deactivated). ^ Solid state clutch relay (pulse width modulated signal; grounded when relay is
on baftery potential when relay is off).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Control Module, Transfer Case > Component
Information > Diagrams > Page 7221
Control Module: Service and Repair
AUTOMATIC FOUR WHEEL DRIVE (A4WD)
Module - Generic Electronic (GEM)/Central Timer (CTM) The GEM/Central Timer Receives
Throttle Position Information From the PCM Only.
Removal 1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to
these charges, damage may result.
Depower the supplemental restraint system (SRS).
2. Remove the audio unit. See: Accessories and Optional Equipment/Radio, Stereo, and Compact
Disc
3. Remove the center instrument panel finish panel.
1. Remove the screws. 2. Remove the center instrument panel finish panel.
^ Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1. Remove the screw. 2. Disconnect the four connectors from the GEM/CTM 3. Remove the
GEM/CTM.
1. NOTE When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy.
2. To install, reverse the removal procedure.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Locations
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions
Four Wheel Drive Selector Relay: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Information > Diagrams > Diagram Information and Instructions > Page 7227
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 7228
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 7229
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Information > Diagrams > Diagram Information and Instructions > Page 7230
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Information > Diagrams > Diagram Information and Instructions > Page 7231
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Information > Diagrams > Diagram Information and Instructions > Page 7232
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Information > Diagrams > Diagram Information and Instructions > Page 7233
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Information > Diagrams > Diagram Information and Instructions > Page 7234
Four Wheel Drive Selector Relay: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Information > Diagrams > Diagram Information and Instructions > Page 7236
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - Transfer Case > Four Wheel Drive Selector Relay > Component
Information > Diagrams > Diagram Information and Instructions > Page 7237
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Information > Diagrams > Diagram Information and Instructions > Page 7238
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Information > Diagrams > Diagram Information and Instructions > Page 7239
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Information > Diagrams > Diagram Information and Instructions > Page 7240
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Information > Diagrams > Diagram Information and Instructions > Page 7241
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Description and Operation
Transmission Mode Switch: Description and Operation
TRANSMISSION CONTROL SWITCH
Transmission Control Switch (TCS)
Transmission Control Switch (TCS)
The Transmission Control Switch (TCS) (Figures 43 and 44) signals the PCM with key power
whenever the TCS is pressed. On vehicles with this feature, the Transmission Control Indicator
Lamp (TCIL) lights when the TCS is cycled to disengage overdrive. The operator of the vehicle
controls the position of the TCS.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications
Digital Transmission Range Sensor: Specifications
Digital transmission range (TR) sensor screws 71 - 97 in.lb
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Digital Transmission Range Sensor <--> [Transmission
Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7250
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Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7251
Digital Transmission Range Sensor: Diagrams
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Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7252
Digital Transmission Range Sensor: Service and Repair
Special Tools
Removal
1. Disconnect the battery ground cable. 2. Raise and support the vehicle.
3. Disconnect the shift cable.
1. Disconnect the shift cable from the manual control lever. 2. Disconnect the shift cable from the
bracket.
4. Disconnect the digital transmission range (TR) sensor electrical connector.
5. Remove the manual control outer lever nut and manual control outer lever.
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6. Remove the screws and the digital TR sensor.
Installation
1. Install the digital TR sensor.
1. Position the digital TR sensor. 2. Loosely install the screws.
2. CAUTION: Tightening one screw before tightening the other may cause the sensor to bind or
become damaged.
Note: The manual lever must he in the neutral position.
Using the special tool, align the digital TR sensor and tighten screws in an alternating sequence.
3. Install the manual control outer lever.
1. Install the manual control outer lever. 2. Install the manual control outer lever nut.
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Position Switch/Sensor, A/T] > Component Information > Specifications > Page 7254
4. Connect the digital transmission range (TR) sensor electrical connector.
5. Connect the shift cable.
1. Connect the shift cable to the bracket. 2. Connect the shift cable to the manual control lever.
6. Verify that the shift cable is adjusted. 7. Lower the vehicle. 8. Connect the battery ground cable.
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
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Specifications > Page 7258
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions
Transmission Speed Sensor: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7261
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7262
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7263
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7264
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7265
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7266
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7267
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7268
Transmission Speed Sensor: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7269
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7270
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7271
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7272
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7273
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7274
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7275
Transmission Speed Sensor: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Diagram Information and Instructions > Page 7276
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 7277
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 7280
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 7281
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 7282
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations
Transmission Temperature Sensor/Switch: Locations
The Transmission Fluid Temperature Sensor is located on the main control body wiring harness
assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7288
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7289
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7290
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7291
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7292
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7293
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7294
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7295
Transmission Temperature Sensor/Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7296
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7297
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7298
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7299
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7301
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 7302
Diagram 29-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Page 7303
Transmission Temperature Sensor/Switch: Description and Operation
Transmission Fluid Temperature (TFT) Sensor
The transmission fluid temperature (TFT) sensor is a thermistor-type sensor that varies a reference
voltage signal. The resistance in the TFT varies with temperature. The powertrain control module
(PCM) monitors the voltage signal across the TFT, and uses this information to determine the
transmission fluid temperature.
The TFT is located on the main control body wiring harness assembly.
The PCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation
and electronic pressure control (EPC).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Specifications
Transmission Speed Sensor: Specifications
Turbine shaft speed (TSS) sensor screw 71 - 97 in.lb
Output shaft speed sensor (OSS) sensor screw 71 - 97 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Specifications > Page 7308
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > 4R70W Transmission
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > 4R70W Transmission > Page 7311
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Diagrams > Page 7312
Transmission Speed Sensor: Description and Operation
OUTPUT SHAFT SPEED SENSOR
The Output Shaft Speed Sensor (OSS), provides the Powertrain Control Module (PCM) with
information about the rotational speed of an output shaft. The PCM uses the information to control
and diagnose powertrain behavior. In some applications, the sensor is also used as the source of
vehicle speed. The sensor may be physically located in different places on the vehicle, depending
upon the specific application. The design of each speed sensor is unique and depends on which
powertrain control feature uses the information generated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift
Transmission Speed Sensor: Service and Repair Transfer Case - Automatic Shift
Output Shaft Speed Sensor-Front
Removal
1. Remove the transfer case shift motor.
2. Remove the front output shaft speed sensor.
1. Remove the bolt. 2. Remove the front output shaft speed sensor.
Installation
1. CAUTION: Make sure the sensor seats flat against the boss.
To install, reverse the removal procedure.
Output Shaft Speed Sensor-Rear
Removal
Warning: The electrical power supply to the air suspension system must be shut off prior to
hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the
air suspension switch located in the rear jack storage area. Failure to do so can result in
unexpected inflation or deflation of the air springs which can result in shifting of the vehicle during
these operations.
1. Raise and support vehicles.
2. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 7315
3. Remove the rear output shaft speed sensor wires from the electrical shift motor connector.
1. Remove the connector interlock. 2. Remove the wires. Use the proper electrical connector pin remover.
4. Remove the bolt and the sensor.
Installation
1. Caution: Make sure the sensor seats flat against the boss
To install, reverse the removal procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 7316
Transmission Speed Sensor: Service and Repair 5R55E
Removal
1. Raise and support the vehicle.
2. Disconnect output shaft speed (OSS) sensor electrical connector.
3. Remove OSS sensor.
1. Remove the OSS sensor screw. 2. Remove the OSS sensor from the transmission.
- Inspect the OSS sensor O-ring for damage. If damaged, replace the O-ring.
Installation
1. Inspect and lubricate O-ring with petroleum jelly.
1. Install the OSS sensor into the transmission. 2. Tighten OSS sensor screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Transmission Speed Sensor, M/T > Component Information >
Service and Repair > Transfer Case - Automatic Shift > Page 7317
2. Connect OSS sensor electrical connector. 3. Lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions
Four Wheel Drive Selector Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7324
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7325
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7326
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7327
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7328
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7329
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7330
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7331
Four Wheel Drive Selector Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7332
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7333
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7334
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7335
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7336
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Diagram Information and Instructions > Page 7337
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Page 7338
Four Wheel Drive Selector Switch: Description and Operation
Switch, Push Button 4x4 Mode
The push button 4x4 mode switch, mounted on the instrument panel, allows the operator to select
the 4x4 Auto, 4x4 High, and 4x4 Low transfer case operating modes. The indicator light, on the
instrument cluster push button, will illuminate only when the 4x4 Low position is engaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - Transfer Case > Four Wheel Drive Selector Switch > Component
Information > Diagrams > Page 7339
Four Wheel Drive Selector Switch: Service and Repair
Removal and Installation
1. Remove and reposition the center instrument panel finish panel.
2. Disconnect the 4x4 mode switch electrical connector.
3. Remove the 4x4 mode switch.
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Locations > Page 7345
ABS Light: Description and Operation
The Antilock Brake System (ABS) uses the yellow ABS warning indicator to alert the driver of a
malfunctions in the ABS.
The yellow ABS warning indicator will come on to warn the driver that the ABS has been turned off
due to a symptom that exists in the ABS. Normal power assist braking remains but wheels can lock
during a panic stop while the yellow ABS warning indicator is illuminated.
The diagnostic procedures must be followed step-by-step in order to correct the condition.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Locations > Page 7349
Acceleration/Deceleration Sensor: Service and Repair
Removal
1. Raise and support the vehicle.
2. Remove the nuts.
3. Unclip the fuel filter from the vehicle frame.
4. Remove the G-switch.
1 Disconnect the G-switch electrical connector.
2 Remove the G-switch.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems >
Acceleration/Deceleration Sensor > Component Information > Locations > Page 7350
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Differential Speed
Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
Anti-lock brake control module bolts 1.8 - 1.9 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 7357
Electronic Brake Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 7358
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 7359
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 7360
Electronic Brake Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 7361
Electronic Brake Control Module: Service and Repair
Removal
1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration
information to the scan tool. This information needs
to be downloaded into the new module once installed.
Disconnect the battery ground cable.
2. Remove the hydraulic control unit bolts.
3. Disconnect the anti-lock brake control module electrical connectors.
4. Remove the anti-lock brake control module.
1 Remove the bolts.
2 Remove the control module.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 7362
1. CAUTION: Once the new module is installed, it is necessary to download the module
configuration information from the scan tool into the
module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Brake line to (EHCU) nuts (M10-1) 12-16 ft.lb
Brake line to (EHCU) nuts (M12-1) 15-18 ft.lb
Electronic hydraulic control unit bolts 9-13 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 7366
Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 7367
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector by lifting up on the release tab.
3. Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU.
1 Remove the bolts.
2 Remove the HCU.
5. Remove the anti-lock brake control module.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 7368
1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: After the HCU is installed, it is necessary to bleed the hydraulic brake system.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications
Wheel Speed Sensor: Specifications
Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb
Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb
Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb
Rear anti-lock brake sensor bolt 20 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Left Front
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Left Front > Page 7374
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front
Wheel Speed Sensor: Service and Repair Sensor, Front
Removal
1. Remove the rotor shield.
2. Disconnect the front anti-lock brake sensor electrical connector.
3. Unclip the front anti-lock brake sensor wire from the vehicle frame.
4. Remove the bolt.
5. Remove the front anti-lock brake sensor.
1 Remove the bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 7377
2 Remove the front anti-lock brake sensor.
Installation
1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High
Temperature 4x4 Front Axle and Wheel Bearing
Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Sensor, Front > Page 7378
Wheel Speed Sensor: Service and Repair Sensor, Rear
Removal
1. Raise and support vehicle.
2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor
before removal.
Remove the rear anti-lock brake sensor. 1
Disconnect the rear anti-lock brake sensor electrical connector.
2 Remove the bolt.
3 Remove the rear anti-lock brake sensor.
Installation
1. NOTE: Thoroughly clean the mounting surface.
NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications
Brake Bleeding: Specifications
Caliper bleeder screw, rear 15 ft.lb
Caliper bleeder screw, front 15 ft.lb
Master cylinder bleeder screw 70-159 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding
Brake Bleeding: Service and Repair Brake Caliper Bleeding
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw. Refer to Specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 7384
Brake Bleeding: Service and Repair Brake System Manual Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the
tube in a container partially filled with clean brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear bleeder screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 7385
6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw.
7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH front disc brake caliper bleeder
screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9.
Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While
the assistant maintains pressure on the brake
pedal, tighten the RH front disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the
LH front disc brake caliper bleeder screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 7386
Brake Bleeding: Service and Repair Brake System Pressure Bleeding
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front disc brake caliper bleeder screw ending
with the LH front disc brake caliper bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 7387
Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU)
NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS)
hydraulic control unit (HCU) has been installed new.
1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash, and follow the scan tool instructions for
bleeding.
2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container
partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then
hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake
fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the
bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front
bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed
procedure as outlined in Steps 3 - 7.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 7388
Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench
Special Tools
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air
can get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When the brake master cylinder has been installed new or the system has been emptied or
partially emptied, it must be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 7389
2. For bench priming, mount the brake master cylinder in a vise.
3. Install short brake tubes with the ends bent into the brake master cylinder reservoir.
^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.
4. For a new brake master cylinder, remove the cruise switch.
5. Fill the cruise switch with the specified brake fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 7390
6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an
assistant slowly pump the brake pedal until clear brake fluid flows from both
brake tubes with no air bubbles.
8. If necessary, install the brake master cylinder into the vehicle.
9. Remove the short brake tubes and install the master cylinder outlet tubes.
10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU).
11. NOTE: Refill the brake master cylinder reservoir as necessary.
Have an assistant depress and hold the brake pedal.
12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles
are seen in the expelled brake fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Brake Caliper Bleeding > Page 7391
14. Repeat the above four steps for the remaining master cylinder outlet tube.
15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other
end in a container partially filled with the specified
brake fluid.
16. Have an assistant pump and then hold firm pressure on the brake pedal.
17. NOTE: Refill the brake master cylinder reservoir as necessary.
Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube.
18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no
air bubbles in the expelled brake fluid. 20. Bleed the brake system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Page 7392
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications
Brake Pedal Assy: Specifications
Brake pedal bracket bolts and nuts 16 - 21 ft.lb
Brake pedal bracket nuts 16 - 21 ft.lb
Brake pedal pivot bolt and nut 15 - 25 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 7396
Brake Pedal Assy: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Brakes and Traction Control; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 7397
Brake Pedal Assy: Service and Repair
Removal
1. NOTE: When removing the stoplight switch, retain the bushing and hairpin clip. They will be
required for installation.
Disconnect the brake booster push rod. 1
Remove the hairpin clip.
2 Separate the stoplight switch and the brake booster push rod from the brake pedal pin.
3 Remove the brake booster push rod bushing.
2. Remove the bulkhead sound insulator.
3. Remove the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 7398
4. CAUTION: Support the brake master cylinder and power brake booster in the engine
compartment.
Remove the brake pedal assembly. 1
Remove the nuts.
2 Remove the brake pedal assembly.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications >
Page 7399
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Locations >
Page 7403
Brake Warning Indicator: Description and Operation
Brake System
The red brake warning light (BRAKE) is used to indicate a low fluid level, brake malfunction or a
parking brake that is not fully released. The brake fluid level switch is located in the brake fluid
reservoir.
The yellow brake warning indicator is used to indicate a malfunction or deactivation of the Anti-lock
Brake System (ABS). It illuminates when triggered by the ABS control module and stays illuminated
as long as the malfunction remains in the system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Front
Brake Caliper: Specifications
Front disc brake caliper anchor plate bolts 72 - 97 ft.lb
Disc brake caliper bolts 21 - 26 ft.lb
Disc brake caliper bleeder screw 13-17 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Specifications > Front > Page 7409
Brake Caliper: Specifications
Brake caliper bolts 20 ft.lb
Caliper flow bolt 23-29 ft.lb
Disc brake caliper bleeder screw 13-17 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front
Brake Caliper: Service and Repair Front
Caliper Removal and Installation
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle, This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Disconnect the front brake hose. 1
Remove the front brake hose bolt.
2 Disconnect the front brake hose.
3 Remove and discard the copper washers. Plug the front brake hose.
4. Remove the disc brake caliper.
1 Remove the disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 7412
5. Inspect the disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. Install the disc brake caliper.
1 Install the disc brake caliper.
2 Install the disc brake caliper bolts.
2. Install the front brake hose.
^ Use new copper washers; connect the front brake hose.
^ Install the front brake hose bolt.
3. Bleed the disc brake caliper.
4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the wheel and tire assembly.
5. Inspect the brake system operation.
Caliper Disassembly and Assembly
Disassembly
1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3.
Secure the disc brake caliper in a vise.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 7413
4. Remove the caliper pistons.
1 Place a block of wood between the caliper bridge and the caliper pistons.
2 Apply low air pressure to the fluid port in the disc brake caliper.
3 Force out the caliper piston to the block of wood.
4 Remove the block of wood and the caliper pistons.
5. Remove and discard the piston seals and boots.
6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.
If the caliper bores are excessively scored or corroded, install a new disc brake caliper.
Assembly
1. CAUTION: Never reuse piston seals or dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance
DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification
ESA-M6C25-A.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 7414
2. Install the caliper pistons.
1 Install the piston seal.
2 Install the piston boot.
3 CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston.
3. Install the disc brake caliper.
Brake Caliper Anchor Plate
Removal
1. NOTE: AWD and 4x4 shown, 4x2 similar.
Remove the pads.
2. Remove the front disc brake caliper anchor plate.
1 Remove the two front disc brake caliper anchor plate bolts.
2 Remove the front disc brake caliper anchor plate.
Installation
1. Install the front disc brake caliper anchor plate.
1 Position the front disc brake caliper anchor plate.
2 Install the front disc brake caliper anchor plate bolts.
2. Install the pads.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 7415
Brake Caliper: Service and Repair Rear
Caliper Removal and Installation
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle
during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Disconnect the brake hose. 1
Remove bolt.
2 Disconnect the rear wheel brake hose.
3 Remove the copper washers and plug the brake hose.
4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are
not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A
(Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A
for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in
contamination and accelerated corrosion or wear of the caliper slide pin mechanism.
Remove the rear disc brake caliper. 1
Remove the brake caliper bolts.
2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 7416
5. Inspect the rear disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct
caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the
rear disc brake caliper.
Install the rear disc brake caliper.
2. Install the rear wheel brake hose.
^ Connect the brake hose and install the caliper flow bolt. ^
Use new copper washers.
3. Bleed the disc brake caliper.
4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the wheel and tire assembly.
5. Verify correct brake operation.
Caliper Disassembly and Assembly
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 7417
Disassembly
1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake
caliper. 3. Secure the rear disc brake caliper in a vise.
4. Remove the rear disc brake piston.
1 Place a block of wood between the caliper bridge and the rear disc brake piston.
2 Apply low air pressure to the fluid port in the rear disc brake caliper.
3 Force the rear disc brake piston out to the block of wood.
4 Remove the block of wood and the rear disc brake piston.
5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the
rear disc brake caliper cylinder bore/piston is
excessively scored or corroded, install a new rear disc brake caliper.
Remove and discard the piston seal and dust boot.
Assembly
CAUTION: Never reuse the piston seal or dust boot.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 7418
1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford
specification ESA-M6C25-A. ^
cylinder bore
^ piston seal
^ rear disc brake piston
^ dust boot
2. Install the piston seal.
3. Install the dust boot.
4. CAUTION: Be careful not to damage or dislodge the piston seal.
Install the rear disc brake piston.
5. Install the rear disc brake caliper.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Front > Page 7419
Rear Disc Brake Adapter
Removal
1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft.
3. Remove the bolts and the rear wheel disc brake adapter.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications
Brake Pad: Specifications
Minimum thickness above the metal backing plate or rivets 0.10 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front
Brake Pad: Service and Repair Front
Removal
1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
3. Remove the wheel and tire assembly.
4. CAUTION: Install a new pad if worn to or past the specified thickness above the metal backing
plate or rivets. Install new pads in complete axle
sets.
Inspect the pads for wear or contamination.
5. Remove the lower caliper bolt.
6. Rotate the disc brake caliper upward.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 7425
7. Remove the pads and the stainless slippers.
1 Remove the pads.
2 Remove the stainless slippers.
8. On 4x2 vehicles, measure the brake disc and hub for minimum thickness.
^ Machine the brake disc first then, install a new brake disc and hub if not within specification.
9. On 4x4 vehicles, measure the brake disc for minimum thickness and for lateral runout.
^ Machine the brake disc first then, install a new brake disc if not within specification.
10. Inspect the disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 7426
1. NOTE: Use a suitable suction device to remove brake fluid from the master cylinder.
NOTE: Clean the anchor plate and stainless slipper surfaces.
NOTE: The inboard pad has a wear indicator tab.
Install the stainless slippers and the pads. 1
Install the stainless slippers.
2 Install the pads.
2. Inspect the anti-rattle spring, install a new spring if worn or damaged.
3. NOTE: If installing new pads, the caliper pistons must be compressed using a C-clamp and a
wooden block. Lower the brake fluid level in the
master cylinder if required.
Rotate the disc brake caliper downward.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 7427
4. Install the caliper bolt.
5. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the wheel and tire assembly.
6. Inspect the brake system operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 7428
Brake Pad: Service and Repair Rear
Removal
1. Remove brake fluid in the master cylinder reservoir until the reservoir is half full.
2. CAUTION: Replace the pads if worn to or past the specified thickness above the metal backing
plate or rivets. Install new pads in complete axle
sets.
Inspect the brake pads for wear or contamination. Install new pads if worn to or past specification.
3. NOTE: It is not necessary to remove the rear wheel brake hose when performing this procedure.
Remove the rear disc brake caliper.
4. CAUTION: Do not allow grease, oil, brake fluid or other contaminants to contact the brake pads.
Remove the brake pads.
5. Retract the caliper piston into the rear disc brake caliper.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Front > Page 7429
6. Remove the slippers.
7. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc.
Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond
specification.
Installation
1. Clean the slipper mating surface, and install the slippers.
2. CAUTION: Install new brake pads in full axle sets. Do not install new brake pads on only one
side of vehicle.
Install the brake pads.
3. Install the rear disc brake caliper. 4. Verify correct brake operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Brake Rotor/Disc
Brake Rotor/Disc: Specifications Brake Rotor/Disc
..............................................................................................................................................................
........................................................ Min Thickness
Front ....................................................................................................................................................
............................................. 0.9646 inch (24.50mm)
Rear .....................................................................................................................................................
..................................................
0.4331 inch (11mm)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Specifications > Brake Rotor/Disc > Page 7434
Brake Rotor/Disc: Specifications
Brake disc shield bolts 7-10 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front
Brake Rotor/Disc: Service and Repair Front
Brake Disc
Removal
1. Remove the front disc brake caliper anchor plate. 2. On 4x4 vehicles, remove the brake disc.
3. On 4x2 vehicles, remove the brake disc and hub as follows:
1 Remove the hub grease cap.
2 Remove the cotter pin.
3 Remove the nut retainer.
4 Remove the spindle nut.
5 Remove the front wheel outer bearing retainer washer.
6 Remove the outer front wheel bearing.
7 Remove the brake disc and hub.
4. Remove the wheel hub grease seal. Remove the front wheel bearing.
Installation
1. On AWD and 4x4 vehicles, position the brake disc to the wheel hub. Use Metal Brake Parts
Cleaner F3AZ-19579-SA or equivalent to clean the
brake disc.
2. On 4x2 vehicles, thoroughly clean and inspect the front wheel bearings and the brake disc and
hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 7437
^ Use Metal Brake Parts Cleaner F3AZ-19579-SA or equivalent.
3. On 4x2 vehicles, lubricate the front wheel bearings.
^ Use Premium Long-Life Grease XG-1-C or-K or equivalent meeting Ford specification
ESA-M1C75-B.
4. On 4x2 vehicles, install a new wheel hub grease seal.
1 Install the inner front wheel bearing.
2 Install a new wheel hub grease seal.
5. On 4x2 vehicles, install the brake disc and hub.
1 Position the brake disc and hub.
2 Install the outer front wheel bearing.
3 Install the front wheel outer bearing retainer washer.
4 Install the spindle nut.
6. Tighten the spindle nut while rotating the brake disc and hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 7438
7. Loosen the spindle nut.
8. Tighten the spindle nut while rotating the brake disc and hub.
9. On 4x2 vehicles, install the following components:
1 Install the nut retainer.
2 Install the cotter pin.
3 Install the hub grease cap.
10. Install the front disc brake caliper anchor plate.
Brake Disc Shield
Removal
1. Remove the brake disc.
2. Remove the brake disc shield.
^ Remove the three brake disc shield bolts and remove the brake disc shield.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 7439
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 7440
Brake Rotor/Disc: Service and Repair Rear
Brake Disc
Removal
1. NOTE: When removing the rear brake disc in this procedure it is not necessary to disconnect the
hydraulic lines.
Remove the rear disc brake caliper.
2. NOTE: If the rear brake disc binds on the rear parking brake shoe and linings, remove the
adjustment hole access plug and contract the parking
brake shoe and lining.
Remove the rear brake disc.
3. CAUTION: Use a hub-mount brake lathe if necessary to machine the rear brake disc.
Measure the rear brake disc, and resurface as necessary. Install a new rear brake disc if beyond
specification.
Installation
1. Follow the removal procedure in reverse order.
Brake Disc Shield
Removal
1. Remove the rear wheel disc brake adapter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information
> Service and Repair > Front > Page 7441
2. Remove the rear wheel disc brake shield.
1 Drill out the rivet.
2 Remove the rear wheel disc brake shield.
Installation
1. NOTE: Because the rear wheel disc brake shield is held in position by the four rear wheel disc
brake adapter bolts, a new rivet is not required.
Seal the rivet hole with Clear Silicone Rubber D6AZ-19562-AA or equivalent meeting Ford
specification ESB-M4G92-A, and install the rear wheel disc brake shield.
2. Install the rear wheel disc brake adapter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Specifications
Brake Drum: Specifications
..............................................................................................................................................................
.............................................. Max Drum Diameter
Rear .....................................................................................................................................................
......................................... 11.0866 inch (281.60mm)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Specifications
Brake Bleeding: Specifications
Caliper bleeder screw, rear 15 ft.lb
Caliper bleeder screw, front 15 ft.lb
Master cylinder bleeder screw 70-159 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding
Brake Bleeding: Service and Repair Brake Caliper Bleeding
1. NOTE: It is not necessary to do a complete brake system bleed if only the disc brake caliper was
disconnected.
Place a box end wrench on the disc brake caliper bleeder screw. Attach a rubber drain tube to the
disc brake caliper bleeder screw, and submerge the free end of the tube in a container partially
filled with clean brake fluid.
2. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 3.
Loosen the disc brake caliper bleeder screw until a stream of brake fluid comes out. While the
assistant maintains pressure on the brake pedal,
tighten the disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
4. Tighten the disc brake caliper bleeder screw. Refer to Specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 7452
Brake Bleeding: Service and Repair Brake System Manual Bleeding
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation of
new components, air can get into the system and cause spongy brake pedal action. This requires
bleeding of the hydraulic system after it has been correctly connected. The hydraulic system can
be bled manually or with pressure bleeding equipment.
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw and submerge the free end of the
tube in a container partially filled with clean brake fluid.
3. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 4.
Loosen the RH rear bleeder screw until a stream of brake fluid comes out. While the assistant
maintains pressure on the brake pedal, tighten the
RH rear bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
5. Tighten the RH rear bleeder screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 7453
6. Repeat Steps 2, 3, 4 and 5 for the LH rear bleeder screw.
7. Place a box end wrench on the RH front disc brake caliper bleeder screw. Attach a rubber drain
tube to the RH front disc brake caliper bleeder
screw, and submerge the free end of the tube in a container partially filled with clean brake fluid.
8. Have an assistant pump the brake pedal and then hold firm pressure on the brake pedal. 9.
Loosen the RH front disc brake caliper bleeder screw until a stream of brake fluid comes out. While
the assistant maintains pressure on the brake
pedal, tighten the RH front disc brake caliper bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
10. Tighten the RH front disc brake caliper bleeder screw. 11. Repeat Steps 7, 8, 9 and 10 for the
LH front disc brake caliper bleeder screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 7454
Brake Bleeding: Service and Repair Brake System Pressure Bleeding
1. Clean all dirt from and remove the brake master cylinder filler cap and fill the brake master
cylinder reservoir with the specified brake fluid.
2. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers
of pressure bleeding equipment. Follow the
instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir, and attach the bleeder tank hose
to the fitting on the adapter.
3. NOTE: Bleed the longest line first. Make sure the bleeder tank contains enough specified brake
fluid to complete the bleeding operation.
Place a box end wrench on the RH rear bleeder screw. Attach a rubber drain tube to the RH rear
bleeder screw, and submerge the free end of the tube in a container partially filled with clean brake
fluid.
4. Open the valve on the bleeder tank.
5. Loosen the RH rear bleeder screw. Leave open until clear, bubble-free brake fluid flows, then
tighten the RH rear bleeder screw and remove the
rubber hose.
6. Continue bleeding the rear of the system, going in order from the LH rear bleeder screw to the
RH front disc brake caliper bleeder screw ending
with the LH front disc brake caliper bleeder screw.
7. Close the bleeder tank valve. Remove the tank hose from the adapter, and remove the adapter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 7455
Brake Bleeding: Service and Repair Four Wheel ABS Hydraulic Control Unit (HCU)
NOTE: This procedure only needs to be performed if the 4-wheel anti-lock brake (4WABS)
hydraulic control unit (HCU) has been installed new.
1. Connect the scan tool DCL cable adapter into the vehicle data link connector (DLC) under the
dash, and follow the scan tool instructions for
bleeding.
2. Clean all dirt from and remove the brake master cylinder filler cap, and fill the brake master
cylinder reservoir with the specified brake fluid.
3. Connect a clear drain tube to the RH rear bleeder screw and the other end in a container
partially filled with recommended brake fluid. 4. Have an assistant pump the brake pedal and then
hold firm pressure on the brake pedal. 5. Loosen the RH rear bleeder screw until a stream of brake
fluid comes out. While the assistant maintains pressure on the brake pedal, tighten the
bleeder screw. ^
Repeat until clear, bubble-free fluid comes out.
^ Refill the brake master cylinder reservoir as necessary.
6. Tighten the bleeder screw. 7. Repeat Steps 3 - 6 for the LH rear bleeder screw, the RH front
bleeder screw and the LH front bleeder screw, in that order. 8. Repeat the conventional bleed
procedure as outlined in Steps 3 - 7.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 7456
Brake Bleeding: Service and Repair Master Cylinder Priming - In-Vehicle or Bench
Special Tools
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
CAUTION: Do not allow the brake master cylinder reservoir to run dry during the bleeding
operation. Keep the brake master cylinder reservoir filled with the specified brake fluid. Never reuse
the brake fluid that has been drained from the hydraulic system.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
NOTE: When any part of the hydraulic system has been disconnected for repair or installation, air
can get into the system and cause spongy brake pedal action. This requires bleeding of the
hydraulic system after it has been correctly connected. The hydraulic system can be bled manually
or with pressure bleeding equipment.
NOTE: When the brake master cylinder has been installed new or the system has been emptied or
partially emptied, it must be primed to prevent air from entering the system.
1. For in-vehicle priming, disconnect the brake lines from the brake master cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 7457
2. For bench priming, mount the brake master cylinder in a vise.
3. Install short brake tubes with the ends bent into the brake master cylinder reservoir.
^ Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification ESA-M6C25-A.
4. For a new brake master cylinder, remove the cruise switch.
5. Fill the cruise switch with the specified brake fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 7458
6. Install the cruise switch. 7. Slowly depress the primary piston or, for in-vehicle priming, have an
assistant slowly pump the brake pedal until clear brake fluid flows from both
brake tubes with no air bubbles.
8. If necessary, install the brake master cylinder into the vehicle.
9. Remove the short brake tubes and install the master cylinder outlet tubes.
10. Loosen a brake outlet tube at the 4WABS hydraulic control unit (HCU).
11. NOTE: Refill the brake master cylinder reservoir as necessary.
Have an assistant depress and hold the brake pedal.
12. Tighten the outlet tube fitting at the HCU. 13. Repeat the above three steps until no air bubbles
are seen in the expelled brake fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Brake Caliper Bleeding > Page 7459
14. Repeat the above four steps for the remaining master cylinder outlet tube.
15. Connect one end of a flexible tube to the master cylinder bleeder screw. Submerge the other
end in a container partially filled with the specified
brake fluid.
16. Have an assistant pump and then hold firm pressure on the brake pedal.
17. NOTE: Refill the brake master cylinder reservoir as necessary.
Loosen the master cylinder bleeder screw until brake fluid flows out of the drain tube.
18. Tighten the master cylinder bleeder screw. 19. Repeat the above three steps until there are no
air bubbles in the expelled brake fluid. 20. Bleed the brake system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information
> Service and Repair > Page 7460
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Front
Brake Caliper: Specifications
Front disc brake caliper anchor plate bolts 72 - 97 ft.lb
Disc brake caliper bolts 21 - 26 ft.lb
Disc brake caliper bleeder screw 13-17 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Specifications > Front > Page 7465
Brake Caliper: Specifications
Brake caliper bolts 20 ft.lb
Caliper flow bolt 23-29 ft.lb
Disc brake caliper bleeder screw 13-17 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front
Brake Caliper: Service and Repair Front
Caliper Removal and Installation
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle, This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Disconnect the front brake hose. 1
Remove the front brake hose bolt.
2 Disconnect the front brake hose.
3 Remove and discard the copper washers. Plug the front brake hose.
4. Remove the disc brake caliper.
1 Remove the disc brake caliper bolts.
2 Lift the disc brake caliper off the front disc brake caliper anchor plate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 7468
5. Inspect the disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. Install the disc brake caliper.
1 Install the disc brake caliper.
2 Install the disc brake caliper bolts.
2. Install the front brake hose.
^ Use new copper washers; connect the front brake hose.
^ Install the front brake hose bolt.
3. Bleed the disc brake caliper.
4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the wheel and tire assembly.
5. Inspect the brake system operation.
Caliper Disassembly and Assembly
Disassembly
1. Remove the disc brake caliper. 2. Drain remaining brake fluid from the disc brake caliper. 3.
Secure the disc brake caliper in a vise.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 7469
4. Remove the caliper pistons.
1 Place a block of wood between the caliper bridge and the caliper pistons.
2 Apply low air pressure to the fluid port in the disc brake caliper.
3 Force out the caliper piston to the block of wood.
4 Remove the block of wood and the caliper pistons.
5. Remove and discard the piston seals and boots.
6. NOTE: Do not hone the caliper bores. Pistons are not available for honed caliper bores.
If the caliper bores are excessively scored or corroded, install a new disc brake caliper.
Assembly
1. CAUTION: Never reuse piston seals or dust boots.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Lubricate the piston boot, caliper piston, piston seal, and cylinder bores with High Performance
DOT 3 Brake Fluid C6AZ-19542-AB or DOT 3 equivalent meeting Ford specification
ESA-M6C25-A.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 7470
2. Install the caliper pistons.
1 Install the piston seal.
2 Install the piston boot.
3 CAUTION: Be careful not to damage or dislodge the piston seal.
Insert the caliper piston.
4 Press the caliper piston into the caliper bore, being careful not to cock the caliper piston.
3. Install the disc brake caliper.
Brake Caliper Anchor Plate
Removal
1. NOTE: AWD and 4x4 shown, 4x2 similar.
Remove the pads.
2. Remove the front disc brake caliper anchor plate.
1 Remove the two front disc brake caliper anchor plate bolts.
2 Remove the front disc brake caliper anchor plate.
Installation
1. Install the front disc brake caliper anchor plate.
1 Position the front disc brake caliper anchor plate.
2 Install the front disc brake caliper anchor plate bolts.
2. Install the pads.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 7471
Brake Caliper: Service and Repair Rear
Caliper Removal and Installation
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch. Failure to do so can
result in unexpected inflation or deflation of the air springs which can result in shifting of the vehicle
during these operations.
Raise and support the vehicle.
2. Remove the wheel and tire assembly.
3. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted or plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Disconnect the brake hose. 1
Remove bolt.
2 Disconnect the rear wheel brake hose.
3 Remove the copper washers and plug the brake hose.
4. CAUTION: Do not remove the guide pins or guide pin boots unless a problem is suspected. The
guide pins are meant to be sealed for life and are
not repairable. Use Silicone Brake Caliper Grease and Dielectric Compound D7AZ-19A331-A
(Motorcraft WA-10) or an equivalent silicone compound meeting Ford specification ESE-M1C171-A
for re-lubing the caliper slide pins. Other greases can swell the guide pin boots, resulting in
contamination and accelerated corrosion or wear of the caliper slide pin mechanism.
Remove the rear disc brake caliper. 1
Remove the brake caliper bolts.
2 Lift the rear disc brake caliper off the rear disc brake caliper anchor plate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 7472
5. Inspect the rear disc brake caliper for leaks.
^ If leaks are found, disassembly is required.
Installation
1. CAUTION: To prevent interference with rear disc brake caliper operation, install only the correct
caliper bolt.
NOTE: Make sure the stainless steel shoe slippers are correctly positioned. Install new slippers if
worn or damaged.
NOTE: When installed, the locator notch on the brake pads will be located at the upper end of the
rear disc brake caliper.
Install the rear disc brake caliper.
2. Install the rear wheel brake hose.
^ Connect the brake hose and install the caliper flow bolt. ^
Use new copper washers.
3. Bleed the disc brake caliper.
4. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the wheel and tire assembly.
5. Verify correct brake operation.
Caliper Disassembly and Assembly
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 7473
Disassembly
1. Remove the rear disc brake caliper. 2. Drain the remaining brake fluid from the rear disc brake
caliper. 3. Secure the rear disc brake caliper in a vise.
4. Remove the rear disc brake piston.
1 Place a block of wood between the caliper bridge and the rear disc brake piston.
2 Apply low air pressure to the fluid port in the rear disc brake caliper.
3 Force the rear disc brake piston out to the block of wood.
4 Remove the block of wood and the rear disc brake piston.
5. NOTE: Do not hone the cylinder bore. Pistons are not available for honed cylinder bores. If the
rear disc brake caliper cylinder bore/piston is
excessively scored or corroded, install a new rear disc brake caliper.
Remove and discard the piston seal and dust boot.
Assembly
CAUTION: Never reuse the piston seal or dust boot.
NOTE: Never reuse brake fluid that has been drained from the hydraulic system or has been
allowed to stand in an open container for an extended period of time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 7474
1. Lubricate the following with High Performance DOT 3 Motor Vehicle Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford
specification ESA-M6C25-A. ^
cylinder bore
^ piston seal
^ rear disc brake piston
^ dust boot
2. Install the piston seal.
3. Install the dust boot.
4. CAUTION: Be careful not to damage or dislodge the piston seal.
Install the rear disc brake piston.
5. Install the rear disc brake caliper.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Front > Page 7475
Rear Disc Brake Adapter
Removal
1. Disconnect the rear parking brake cable guide. 2. Remove the axle shaft.
3. Remove the bolts and the rear wheel disc brake adapter.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications
Brake Fluid: Specifications
Brake Fluid High Performance DOT 3
Dot 4 may be used if Dot 3 is not available.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information
> Specifications > Page 7479
Brake Fluid: Description and Operation
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
Clean, fresh Ford High Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid
meeting Ford specification ESA-M6C25-A is the only brake fluid that should be used in Ford
vehicles. ^
Do not reuse brake fluid drained or bled from the system.
^ Do not use brake fluid that has been stored in an open container.
^ Do not use contaminated brake fluid.
^ Do not mix different types of brake fluid.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Locations > Page 7483
Brake Fluid Level Sensor/Switch: Description and Operation
The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder
reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the
brake master cylinder reservoir.
When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the
floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate.
Loss of brake fluid will cause this system to activate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch
> Component Information > Specifications
Brake Fluid Pressure Sensor/Switch: Specifications
Brake pressure switch 11-14 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications
Brake Hose/Line: Specifications
Front brake hose bolt 23-29 ft.lb
Front brake hose bracket 10-12 ft.lb
Front brake tube 12-14 ft.lb
Rear brake hose to caliper bolt 23 - 29 ft.lb
Brake hose bracket to rear axle bolt 10 - 12 ft.lb
Rear brake tube fitting 12 - 14 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Page 7490
Brake Hose/Line: Service and Repair
CAUTION: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which could
result in brake tube failure.
If a section of brake tube is damaged, the entire section must be installed new with a tube of the
same type, size, shape and length. When installing hydraulic brake tubing, hoses, or connectors,
tighten all connections to specifications. After installation, bleed the brake system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Specifications
Brake Proportioning/Combination Valve: Specifications
Brake pressure control valve 10 - 16 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Brake line to (EHCU) nuts (M10-1) 12-16 ft.lb
Brake line to (EHCU) nuts (M12-1) 15-18 ft.lb
Electronic hydraulic control unit bolts 9-13 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 7497
Hydraulic Control Assembly - Antilock Brakes: Testing and Inspection
For further information regarding this component and the system that it is a part of, please refer to
Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 7498
Hydraulic Control Assembly - Antilock Brakes: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Disconnect the electrical connector by lifting up on the release tab.
3. Disconnect the brake lines from the hydraulic control unit (HCU).
4. Remove the HCU.
1 Remove the bolts.
2 Remove the HCU.
5. Remove the anti-lock brake control module.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock
Brakes > Component Information > Specifications > Page 7499
1. WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes.
Wash hands thoroughly after handling. If
brake fluid contacts eyes, flush eyes with running water for 15 minutes. Get medical attention if
irritation persists. If taken internally, drink water and induce vomiting. Get medical attention
immediately.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
CAUTION: After the HCU is installed, it is necessary to bleed the hydraulic brake system.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Brake Master Cylinder
Brake Master Cylinder: Specifications
Brake master cylinder nut 14 - 19 ft.lb
Master cylinder brake tube nuts 12 - 14 ft.lb
Master cylinder bleeder screw 6 - 13 ft.lb
Brake master cylinder tube fitting, front 11 - 14 ft.lb
Brake master cylinder tube fitting, rear 11 - 14 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Brake Master Cylinder > Page 7504
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Specifications > Page 7505
Brake Master Cylinder: Description and Operation
The brake master cylinder is a dual-piston type.
The brake master cylinder is assisted by a power brake booster.
The following conditions are considered normal and not indications that the brake master cylinder
is in need of repair or replacement: ^
Low brake fluid level detected without signs of leakage. This condition is caused by displacement
of brake fluid from the brake master cylinder reservoir into the disc brake calipers/rear disc brake
calipers to compensate for normal brake wear. Fill the brake master cylinder reservoir with High
Performance DOT 3 Brake Fluid C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford
specification ESA-M6C25-A.
^ A momentary or slight squirt of brake fluid inside the brake master cylinder reservoir upon
application of the brake pedal.
^ A trace of brake fluid found on the outside of the power brake booster below the brake master
cylinder mounting flange. This condition results from the lubricating action of the brake master
cylinder wiping seal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > General Procedures
Brake Master Cylinder: Testing and Inspection General Procedures
Normal Conditions
The following conditions are considered normal and are not indications that the brake master
cylinder is in need of service.
Condition 1: During normal operation of the brake master cylinder, the fluid level in the brake
master cylinder reservoir will rise during brake application and fall during release. The net fluid level
(after brake application and release) will remain unchanged. Condition 2: A trace of brake fluid will
exist on the booster shell below the master cylinder mounting flange. This results from the normal
lubricating action of the master cylinder bore and seal. Condition 3: Fluid level will decrease with
pad wear.
Abnormal Conditions
Changes in brake pedal feel or travel are indicators that something could be wrong in the brake
system. Refer to the Symptom Chart at Brakes and Traction Control/Testing and Inspection for
abnormal condition diagnosis.
Bypass Condition Test
1. Disconnect the brake lines at the brake master cylinder. 2. Plug the outlet ports of the brake
master cylinder. 3. Apply the brakes. If brake pedal height cannot be maintained, the brake master
cylinder has an internal leak and must be rebuilt or installed new.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > General Procedures > Page 7508
Brake Master Cylinder: Testing and Inspection Compensator Port Check
The purpose of the compensator ports in the brake master cylinder is to supply any additional
brake fluid required by the system due to brake pad wear and to allow brake fluid returning from the
brake lines to the brake master cylinder to enter the brake master cylinder reservoir.
The returning brake fluid will cause a slight turbulence in the brake master cylinder reservoir.
Turbulence seen in the brake master cylinder reservoir upon release of the brake pedal is normal
and shows that the compensating ports are not plugged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Testing and Inspection > Page 7509
Brake Master Cylinder: Adjustments
Master Cylinder Push Rod Adjustment
1. Remove the brake master cylinder.
2. CAUTION: Do not apply the brake pedal with the master cylinder removed from the booster.
Adjust the power brake booster to brake master cylinder push rod, vacuum applied. 1
Measure the power brake booster to brake master cylinder push rod.
2 If necessary, adjust the screw to the correct length.
3. Install the brake master cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Removal and Installation
Brake Master Cylinder: Service and Repair Removal and Installation
Removal
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
1. Disconnect the brake fluid level warning switch.
2. On cruise control equipped vehicles, disconnect the brake pressure switch.
3. Disconnect the two brake lines, and plug the lines and the brake master cylinder ports.
4. On vehicles with 4.0L engine, remove the wiring retainer clip from the master cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Removal and Installation > Page 7512
5. Remove the brake master cylinder.
1 Remove the nuts.
2 Remove the brake master cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Bleed the brake master cylinder before installation.
^ Bleed the brake system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component
Information > Service and Repair > Removal and Installation > Page 7513
Brake Master Cylinder: Service and Repair Brake Fluid Reservoir
Removal
WARNING: Brake fluid contains polyglycol ethers and polyglycols. Avoid contact with eyes. Wash
hands thoroughly after handling. If brake fluid contacts eyes, flush eyes with running water for 15
minutes. Get medical attention if irritation persists. If taken internally, drink water and induce
vomiting. Get medical attention immediately.
1. Disconnect the brake master cylinder fluid level warning switch. 2. Use a suitable suction device
to drain the brake master cylinder reservoir.
3. Carefully pry up on the brake master cylinder reservoir to remove.
Installation
1. NOTE: Whenever installing a new brake master cylinder reservoir, install new grommets.
Install the brake master cylinder reservoir. 1
Lubricate the two grommets with High Performance DOT 3 Brake Fluid C6AZ-19542-AB or
equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A, and insert the grommets in the
brake master cylinder.
2 Press the brake master cylinder reservoir into the grommets until it snaps.
3 Connect the brake master cylinder fluid level warning switch.
4 Fill the brake master cylinder reservoir with High Performance DOT 3 Brake Fluid
C6AZ-19542-AB or equivalent DOT 3 fluid meeting Ford specification ESA-M6C25-A.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Specifications
Parking Brake Cable: Specifications
Torque Specifications
Parking brake cable and conduit clip bolt
..................................................................................................................................... 15-20 Nm
(11-14 lb.ft) Parking brake cable retainer clip bolt
.............................................................................................................................................. 6-8 Nm
(54-70 in.lb)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front
Parking Brake Cable: Service and Repair Cable and Conduit - Front
Removal
1. Remove the parking brake control.
2. Disconnect the front parking brake cable from the parking brake control.
3. Remove the front parking brake cable and conduit housing.
1 Compress the front parking brake cable and conduit-to-parking brake control clip.
2 Remove the front parking brake cable and conduit housing.
Installation
1. Follow the removal procedure in reverse order.
^ Make sure cable is routed through loop on take up spool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 7520
Parking Brake Cable: Service and Repair Cable and Conduit - Rear
Removal
1. NOTE: Make sure the parking brake control is fully released.
Relieve the tension on the parking brake system. 1
Pull the front parking brake cable and conduit.
2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
3. Remove the tire and wheel assembly.
4. NOTE: Disconnect the parking brake intermediate cable from the locating hole end of the
connector.
Disconnect the parking brake intermediate cable from the LH parking brake rear cable and conduit.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 7521
5. Separate the RH parking brake rear cable and conduit from the LH parking brake rear cable and
conduit at the parking brake cable equalizer.
6. Remove the RH parking brake rear cable and conduit from the parking brake cable bracket
1 Compress the parking brake cable clip.
2 Remove the RH parking brake rear cable and conduit from the parking brake cable bracket.
7. Remove the RH parking brake rear cable and conduit to LH parking brake rear cable and conduit
clip.
8. Remove the RH parking brake rear cable and conduit from the rear parking brake cable retainer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 7522
9. Remove the RH parking brake rear cable and conduit to the RH hydraulic brake line clip.
10. Remove the parking brake cable retainer clip.
1 Remove the parking brake cable retainer clip bolt.
2 Remove the parking brake cable retainer clip.
11. Unclip the parking brake rear cable and conduit from the brake line clip on top of the rear axle
housing.
12. Compress the retainer and release the parking brake rear cable and conduit from the rear disc
brake caliper anchor plate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 7523
13. Unclip the parking brake rear cable and conduit from the parking brake lever.
Installation
1. Clip the parking brake rear cable and conduit to the parking brake lever.
2. Connect the parking brake rear cable and conduit to the rear disc brake caliper anchor plate.
3. Clip the parking brake rear cable and conduit to the brake line clip on top of the rear axle
housing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 7524
4. Install the parking brake cable retainer clip.
1 Position the parking brake cable retainer clip.
2 Install the parking brake cable retainer clip bolt.
5. Install the RH parking brake rear cable and conduit to the RH hydraulic brake line clip.
6. Hook the RH parking brake rear cable and conduit to the rear parking brake cable retainer.
7. Install the RH parking brake rear cable and conduit to the LH parking brake rear cable and
conduit clip.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 7525
8. Connect the RH parking brake rear cable and conduit to the parking brake cable bracket.
1 Install the RH parking brake rear cable and conduit to the parking brake cable bracket.
2 Push the RH parking brake rear cable and conduit into the parking brake cable bracket until the
parking brake cable and conduit clip is seated.
9. Connect the RH parking brake rear cable and conduit to the LH parking brake rear cable and
conduit at the parking brake cable equalizer.
10. Connect the parking brake intermediate cable to the LH parking brake rear cable and conduit.
11. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the front wheel and tire assemblies.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Cable and Conduit - Front > Page 7526
12. Apply tension to the parking brake system.
1 Pull down on the front parking brake cable and conduit.
2 Remove the retainer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications
Parking Brake Control: Specifications
Torque Specifications Parking brake control bolts ..............................................................................
................................................................................. 17-23 Nm (13-17 lb.ft)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 7530
Parking Brake Control: Service and Repair
Removal
1. NOTE: Make sure the parking brake control is fully released.
Relieve the tension on the parking brake system. 1
Pull down on the parking brake intermediate cable.
2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer in the parking brake control.
2. Remove the LH front fender apron.
3. Remove the front parking brake cable and conduit from the retainer clip.
1 Remove the front parking brake cable and conduit retainer clip bolt.
2 Remove the front parking brake cable and conduit retainer clip.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 7531
4. NOTE: Disconnect the front parking brake cable and conduit at the locating hole end of the
connector.
Disconnect the front parking brake cable and conduit from the parking brake intermediate cable.
5. Remove the front parking brake cable and conduit from the bracket.
1 Compress the retainer from the front parking brake cable and conduit from the bracket.
2 Remove the front parking brake cable and conduit from the bracket.
6. Remove the parking brake release mounting bolts.
7. Remove the parking brake control and front parking brake cable and conduit.
1 Disconnect the parking brake signal switch electrical connector.
2 Remove the three parking brake control bolts.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component
Information > Specifications > Page 7532
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Release Switch >
Component Information > Specifications
Parking Brake Release Switch: Specifications
Parking brake remote release to instrument panel
......................................................................................................................... 2.1-2.9 Nm (19-25 ft.
lbs)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications
Parking Brake Shoe: Specifications
Parking brake shoes and lining minimum thickness 0.04 ft
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 7539
Parking Brake Shoe: Service and Repair
Special Service Tool(s)
Removal
1. NOTE: Make sure the parking brake control is fully released.
Relieve the tension on the parking brake system. 1
Pull the front parking brake cable and conduit.
2 Insert a 4 mm (5/32 inch) drill bit or equivalent retainer.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
3. Remove the tire and wheel assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 7540
4. Remove the rear brake disc.
5. Remove the brake shoe retracting spring.
6. Remove the brake shoe adjusting screw spring.
7. Remove the brake adjuster screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 7541
8. Remove the rear brake shoe hold-down springs.
9. Remove the rear brake shoes and linings along with the inboard brake shoe retracting spring.
10. Inspect the components for excessive wear or damage and install new as required.
Installation
1. NOTE: Lubricate the brake shoe contact point before installation of rear shoes using Silicone
Brake Caliper Grease and Dielectric Compound
D7AZ-19A331-A (Motorcraft WA-10) or an equivalent silicone compound meeting Ford
Specification ESE-M1C171-A.
Install the rear brake shoes and linings along with the inboard brake shoe retracting spring.
2. Install the brake shoe hold-down springs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 7542
3. Install the brake adjuster screw.
4. Install the brake shoe adjusting screw spring.
5. Install the outboard brake shoe retracting spring.
6. Use Brake Adjusting Gauge to measure the inside diameter of the drum portion of the rear brake
disc.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 7543
7. Use Brake Adjusting Gauge to set the rear brake shoe and lining diameter to 0.5 mm (0.020
inch) less than the inside diameter of the drum portion
of the rear brake disc.
8. Install the rear brake disc.
9. WARNING: Always remove any corrosion, dirt or foreign material present on the mounting
surfaces of the wheel or the surface of the
wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without correct
metal to metal contact at the wheel mounting surfaces can cause the lug nuts to loosen and come
off while the vehicle is in motion, causing loss of control.
Clean the wheel hub mounting surface.
10. NOTE: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the wheel and tire assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 7544
11. Apply tension to the parking brake cable system.
1 Hold the front parking brake cable and conduit taut.
2 Remove the retainer from the parking brake control.
12. Check the operation of the parking brake.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Specifications > Page 7545
Special Tools
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications
Vacuum Brake Booster: Specifications
Power brake booster push rod length 0.99 - 1.01 in
Power brake booster nuts 15 - 20 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 7550
Vacuum Brake Booster: Description and Operation
The power brake booster: ^
is a dual diaphragm, vacuum assisted power brake booster.
^ is located on the LH side of the bulkhead in the engine compartment, between the brake pedal
and brake master cylinder.
^ is divided into separate chambers by the diaphragm.
^ will not operate if vacuum is restricted or if any of the vacuum related power brake components
fail.
^ is installed as an assembly.
If the power assist fails, the brake system will continue to operate with increased brake pedal effort.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Brake Booster - Operational Check
Vacuum Brake Booster: Testing and Inspection Brake Booster - Operational Check
1. Check the hydraulic brake system for leaks or insufficient fluid. 2. With the transmission in
NEUTRAL, stop the engine and apply the parking brake control. Apply the brake pedal several
times to exhaust all
vacuum in the system.
3. Apply the brake pedal and hold it in the applied position. Start the engine. If the vacuum system
is operating, the brake pedal will tend to move
downward under constant foot pressure. If no motion is felt, the power brake booster system is not
functioning. Continue the test with the following steps.
4. Remove the vacuum booster hose from check valve connection. Manifold vacuum must be
available at the check valve end of the vacuum booster
hose with the engine at idle speed and the transmission in NEUTRAL. If the manifold vacuum is
available to the power brake booster, connect the vacuum booster hose to the power brake booster
check valve and repeat Steps 2 and 3 above.
5. Check and if no downward movement of the brake pedal is felt, install a new power brake
booster. 6. Operate the engine a minimum of 10 seconds at fast idle. Stop the engine, and let the
vehicle stand for 10 minutes. Then apply the brake pedal with
approximately 89 Nm (20 lbs.) of force. The brake pedal feel should be the same as that noted with
the engine operating. If the brake pedal feels hard (no power assist), install a new check valve and
retest. If the brake pedal feels spongy, bleed the hydraulic system to remove air.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Brake Booster - Operational Check > Page 7553
Vacuum Brake Booster: Testing and Inspection Vacuum Connection Checks
Inspect all hoses and connections. All unused vacuum connectors should be capped. Hoses and
their connections should be correctly secured and in good condition with no holes, soft or collapsed
areas.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Page 7554
Vacuum Brake Booster: Service and Repair
Removal
1. Remove the brake master cylinder.
2. Disconnect the power brake booster hose.
1 Compress the clamp.
2 Disconnect the power brake booster hose.
3. Disconnect the brake pedal to power brake booster push rod.
1 Remove the self-locking pin.
2 Remove the stoplight switch and the brake booster push rod from the brake pedal pin.
3 Remove the brake booster push rod bushing.
4. Remove the bulkhead sound insulator.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Testing and Inspection > Page 7555
5. NOTE: Support the power brake booster.
Remove the power brake booster. 1
Remove the nuts.
2 Remove the power brake booster.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Description and Operation
Vacuum Brake Booster Check Valve: Description and Operation
The power brake booster check valve: ^
is located on the front of the power brake booster.
^ is positioned between the power brake booster and the power brake booster hose.
^ closes when the engine is turned off.
^ in the closed position, traps engine vacuum in the power brake booster.
^ retains vacuum to provide several power assisted brake applications with the engine off.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve >
Component Information > Description and Operation > Page 7559
Vacuum Brake Booster Check Valve: Testing and Inspection
The function of the power brake booster check valve is to allow manifold vacuum to enter the
power brake booster and prevent the escape of vacuum in case manifold vacuum is lost during
sustained full throttle operation.
To test the function of the power brake booster check valve: ^
Start and run the engine for at least 10 seconds.
^ Operate the brake pedal to check for power assist.
^ Disconnect the vacuum booster hose from the power brake booster. Do not remove the power
brake booster check valve from the power brake booster.
^ There should be enough vacuum retained in the power brake booster for at least one more
power-assisted brake operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
Anti-lock brake control module bolts 1.8 - 1.9 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 7564
Electronic Brake Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 7565
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 7566
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 7567
Electronic Brake Control Module: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Antilock Brakes / Traction Control Systems; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 7568
Electronic Brake Control Module: Service and Repair
Removal
1. CAUTION: Prior to removal of the module, it is necessary to upload module configuration
information to the scan tool. This information needs
to be downloaded into the new module once installed.
Disconnect the battery ground cable.
2. Remove the hydraulic control unit bolts.
3. Disconnect the anti-lock brake control module electrical connectors.
4. Remove the anti-lock brake control module.
1 Remove the bolts.
2 Remove the control module.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 7569
1. CAUTION: Once the new module is installed, it is necessary to download the module
configuration information from the scan tool into the
module.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Locations > Page 7574
Acceleration/Deceleration Sensor: Service and Repair
Removal
1. Raise and support the vehicle.
2. Remove the nuts.
3. Unclip the fuel filter from the vehicle frame.
4. Remove the G-switch.
1 Disconnect the G-switch electrical connector.
2 Remove the G-switch.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control >
Acceleration/Deceleration Sensor > Component Information > Locations > Page 7575
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Locations > Page 7579
Brake Fluid Level Sensor/Switch: Description and Operation
The brake master cylinder fluid level warning switch is an integral part of the brake master cylinder
reservoir. It consists of a float containing a magnet and a reed switch mounted in the bottom of the
brake master cylinder reservoir.
When the brake fluid in the brake master cylinder reservoir gets to a predetermined level, the
floating magnet actuates the reed switch, causing the red brake warning indicator to illuminate.
Loss of brake fluid will cause this system to activate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Pressure Sensor/Switch > Component Information > Specifications
Brake Fluid Pressure Sensor/Switch: Specifications
Brake pressure switch 11-14 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Differential
Speed Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking
Brake Release Switch > Component Information > Specifications
Parking Brake Release Switch: Specifications
Parking brake remote release to instrument panel
......................................................................................................................... 2.1-2.9 Nm (19-25 ft.
lbs)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications
Wheel Speed Sensor: Specifications
Front anti-lock brake sensor bolt (4x2) 71 - 88 ft.lb
Front anti-lock brake sensor wire retaining bolt (4x4) 62 - 80 ft.lb
Front anti-lock brake sensor bolt (4x4) 62 - 80 ft.lb
Rear anti-lock brake sensor bolt 20 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Left Front
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Left Front > Page 7594
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Sensor, Front
Wheel Speed Sensor: Service and Repair Sensor, Front
Removal
1. Remove the rotor shield.
2. Disconnect the front anti-lock brake sensor electrical connector.
3. Unclip the front anti-lock brake sensor wire from the vehicle frame.
4. Remove the bolt.
5. Remove the front anti-lock brake sensor.
1 Remove the bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 7597
2 Remove the front anti-lock brake sensor.
Installation
1. NOTE: Plug the sensor mount opening and thoroughly clean the mounting surface. Apply High
Temperature 4x4 Front Axle and Wheel Bearing
Grease E8TZ-19590-A meeting Ford specification ESA-M1Cl98-A.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Sensor, Front > Page 7598
Wheel Speed Sensor: Service and Repair Sensor, Rear
Removal
1. Raise and support vehicle.
2. NOTE: Clean off dirt and debris that may have collected around the rear anti-lock brake sensor
before removal.
Remove the rear anti-lock brake sensor. 1
Disconnect the rear anti-lock brake sensor electrical connector.
2 Remove the bolt.
3 Remove the rear anti-lock brake sensor.
Installation
1. NOTE: Thoroughly clean the mounting surface.
NOTE: Inspect the anti-lock brake sensor O-ring for damage; lightly lubricate the O-ring with High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
7609
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Removal
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
7610
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the bearing and the gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page
7611
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Note: Use a new ignition switch lock cylinder.
Follow the removal procedure in reverse order. ^
Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch
> Component Information > Locations > Page 7615
Neutral Safety Switch: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 7620
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 7621
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 7622
Starter Relay: Service Precautions
WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE
THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE
PROTECTIVE CAPS ARE IN PLACE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 7623
Starter Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 7624
Starter Relay: Service and Repair
REMOVAL
WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE
THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE
PROTECTIVE CAPS ARE IN PLACE.
1. Disconnect the battery ground cable.
2. Disconnect the starter motor solenoid relay switch wiring.
1 Remove the protective cover.
2 Disconnect the push-on electrical connector.
3 Remove the nuts.
4 Remove the cable.
3. Remove the starter motor solenoid relay switch.
1 Remove the engine sensor/generator wires.
2 Remove the bolts and ground wire.
3 Remove the starter motor solenoid relay switch.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications
Battery Cable: Specifications
Battery Cable Clamp Bolts 7-10 Nm
Battery Cable Bolts 7-10 Nm
Battery Ground Cable To Frame Bolt 11-13 Nm
Battery Ground Cable To Radiator Support Nut 11-13 Nm
Battery Ground Cable To Starter Motor Stud Nut 23-32 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications >
Page 7629
Battery Cable: Service and Repair
REMOVAL
1. Disconnect the battery cables.
1 Disconnect the battery ground cable.
2 Disconnect the battery to starter relay cable.
2. Remove the three battery cable wire harness pushpins.
3. Remove the nut and the chassis ground cable. 4. Raise and support the vehicle; refer to
Maintenance/Service and Repair.
5. Remove the bolt, the frame ground cable, and the bracket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications >
Page 7630
6. Remove the bolt from the battery cable bracket.
7. Remove the battery ground cable nut from the starter motor stud and remove the battery ground
cable.
8. Remove the starter motor wiring harness.
1 Remove the push-on electrical connector.
2 Remove the starter motor wiring harness to starter motor nut and wire. ^
Remove battery cable wiring harness.
INSTALLATION
1. Install the starter motor wiring harness.
1 Install the starter motor wiring harness to starter motor wire and nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications >
Page 7631
2 Install the push-on electrical connector.
2. Install the battery ground cable to the starter motor stud and install the nut.
3. Install the battery cable bracket and the bolt.
4. Position the frame ground cable, bracket and install the bolt. 5. Lower the vehicle.
6. Install the chassis ground cable and the nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Specifications >
Page 7632
7. Install the three battery cable wire harness pushpins.
8. Connect the battery to starter relay cable and then connect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven to relearn
the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Alternator Pulley > Component
Information > Service and Repair
Alternator Pulley: Service and Repair
REMOVAL
1. Disconnect the battery. For additional information, refer to Battery Service and Repair. 2.
Remove the Generator (GEN). For additional information, refer to Generator Service and Repair.
3. Remove the (A) nut and the (B) generator pulley.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Specifications
Voltage Regulator: Specifications
Voltage Regulator/Brush Holder Screws 2.3-3.4 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Specifications > Page 7641
Voltage Regulator: Service and Repair
REMOVAL
1. Remove the generator. For additional information, refer to Generator Service and Repair.
2. Remove the voltage regulator/brush holder assembly.
1 Remove the screws.
2 Remove the voltage regulator/brush holder assembly.
INSTALLATION
1. Install the voltage regulator/brush holder assembly.
1 Depress the brushes and insert a wire to hold brushes during installation.
2 Install the voltage regulator/brush holder assembly.
3 Install the screws and remove the wire.
2. Install the generator. For additional information, refer to Generator Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Switch > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Functional
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7651
Ignition Switch Lock Cylinder: Service and Repair Ignition Lock Cylinder - Non Functional
Removal
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7652
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
5. Remove the bearing retainer.
6. Remove the bearing and the gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Service and Repair > Ignition Lock Cylinder - Functional > Page 7653
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Note: Use a new ignition switch lock cylinder.
Follow the removal procedure in reverse order. ^
Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 7657
Neutral Safety Switch: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component
Information > Locations > Page 7662
Starter Drive/Bendix: Testing and Inspection
STARTER DRIVE AND FLYWHEEL RING GEAR INSPECTION
1. Remove the starter motor; refer to Starter Motor Service and Repair.
2. Check the wear patterns on the starter drive gear and the flywheel ring gear. If the wear pattern
is normal, install the starter motor; refer to Starter
Motor Service and Repair.
3. If the starter drive gear and the flywheel ring gear are not fully meshing and both of the gears are
scored or damaged, replace the starter motor;
refer to Starter Motor Service and Repair. If necessary, replace the flywheel; refer to Engine.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 7666
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 7667
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 7668
Starter Relay: Service Precautions
WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE
THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE
PROTECTIVE CAPS ARE IN PLACE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 7669
Starter Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations >
Page 7670
Starter Relay: Service and Repair
REMOVAL
WARNING: WHEN PERFORMING MAINTENANCE ON THE STARTING SYSTEM BE AWARE
THAT HEAVY GAUGE LEADS ARE CONNECTED DIRECTLY TO THE BATTERY. MAKE SURE
PROTECTIVE CAPS ARE IN PLACE.
1. Disconnect the battery ground cable.
2. Disconnect the starter motor solenoid relay switch wiring.
1 Remove the protective cover.
2 Disconnect the push-on electrical connector.
3 Remove the nuts.
4 Remove the cable.
3. Remove the starter motor solenoid relay switch.
1 Remove the engine sensor/generator wires.
2 Remove the bolts and ground wire.
3 Remove the starter motor solenoid relay switch.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Specifications
Starter Solenoid: Specifications
Solenoid Bolts 5-10 Nm
Starter Solenoid B-Terminal Nut 10-15 Nm
Starter Solenoid S-Terminal Nut 5-7 Nm
B+ Terminal Nut 9-12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information >
Specifications > Page 7674
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Locations > Auxilirary Relay Box #1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Locations > Auxilirary Relay Box #1 > Page 7683
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Locations > Auxilirary Relay Box #1 > Page 7684
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Locations > Auxilirary Relay Box #1 > Page 7685
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Locations > Auxilirary Relay Box #1 > Page 7686
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions
Electrical Accessory Panel: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7689
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7690
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7691
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7692
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7693
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7694
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7695
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7696
Electrical Accessory Panel: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7697
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7698
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7699
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7700
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7701
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel >
Component Information > Diagrams > Diagram Information and Instructions > Page 7702
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7711
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7712
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7713
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7714
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7715
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7716
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7717
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug
> 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7718
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7724
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7725
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7726
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7727
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7728
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7729
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7730
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electronic Noise Suppressor >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: >
02-16-4 > Aug > 02 > Audio System - Whining/Buzzing Noise From Speakers > Page 7731
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7736
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7737
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7738
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7739
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7740
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7741
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7742
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7743
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7744
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7745
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7746
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions
Fuse: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7749
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7750
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7751
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7752
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7753
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7754
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7755
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7756
Fuse: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7757
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7758
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7759
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7760
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7761
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Diagrams > Diagram Information and Instructions > Page 7762
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7765
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7766
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7767
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7768
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7769
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7770
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7771
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7772
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7773
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7774
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7775
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7780
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7781
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7782
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7783
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7784
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7785
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7786
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7787
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7788
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7789
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7790
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions
Fuse Block: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7793
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7794
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7795
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7796
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7797
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7798
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7799
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7800
Fuse Block: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7801
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7802
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7803
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7804
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7805
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Diagrams > Diagram Information and Instructions > Page 7806
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7809
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7810
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7811
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7812
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7813
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7814
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7815
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7816
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7817
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7818
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information
> Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7819
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component
Information > Specifications
Ground Strap: Specifications
Intake Manifold Ground Strap Nut
...................................................................................................................................................... 7-9
Nm (62-80 Lb-In) Battery Ground Cable Screw
..............................................................................................................................................................
7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt
.............................................................................................................................................. 8.9-12.1
Nm (79-107 Lb-In)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component
Information > Specifications > Page 7823
Ground Strap: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the nut and washer (A) attaching the ground strap (B) to the stud.
3. Remove the fastener from the rear of the right cylinder head and ensure that the mounting
surfaces of the studs are free of dirt and corrosion.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Ground Strap > Component
Information > Specifications > Page 7824
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Micro ISO Relay > Component
Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Mini ISO Relay > Component
Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C113
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C113 > Page 7835
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C113 > Page 7836
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Component Information > Diagrams > C113 > Page 7837
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Component Information > Diagrams > C113 > Page 7838
Multiple Junction Connector: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > C113 > Page 7839
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Component Information > Diagrams > C113 > Page 7840
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Component Information > Diagrams > C113 > Page 7841
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Component Information > Diagrams > C113 > Page 7842
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Component Information > Diagrams > C113 > Page 7843
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Component Information > Diagrams > C113 > Page 7844
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Component Information > Diagrams > C113 > Page 7845
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Component Information > Diagrams > C113 > Page 7846
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Component Information > Diagrams > C113 > Page 7847
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Component Information > Diagrams > C113 > Page 7848
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Component Information > Diagrams > C113 > Page 7849
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Component Information > Diagrams > C113 > Page 7850
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Component Information > Diagrams > C113 > Page 7851
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Component Information > Diagrams > C113 > Page 7852
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Component Information > Diagrams > C113 > Page 7853
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Component Information > Diagrams > C113 > Page 7854
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Component Information > Diagrams > C113 > Page 7855
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Component Information > Diagrams > C113 > Page 7856
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Component Information > Diagrams > C113 > Page 7857
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Component Information > Diagrams > C113 > Page 7858
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Component Information > Diagrams > C113 > Page 7859
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Component Information > Diagrams > C113 > Page 7860
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Component Information > Diagrams > C113 > Page 7862
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Component Information > Diagrams > C113 > Page 7864
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Component Information > Diagrams > C113 > Page 7865
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Component Information > Diagrams > C113 > Page 7867
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Component Information > Diagrams > C113 > Page 7869
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations
Power Distribution Relay: Locations
Trailer Tow Park Lamp Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 7873
4 Door W/Electronics Group
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 7874
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations > Page 7875
Power Distribution Relay: Testing and Inspection
Trailer Tow Park Lamp Relay Test
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Micro ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Mini ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations
Power Distribution Relay: Locations
Trailer Tow Park Lamp Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7886
4 Door W/Electronics Group
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Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7887
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations > Page 7888
Power Distribution Relay: Testing and Inspection
Trailer Tow Park Lamp Relay Test
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7893
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7894
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7895
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7896
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7897
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7898
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7899
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7900
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7901
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7902
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central
Junction Box (CJB) > Page 7903
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7906
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7907
Relay Box: Diagrams Auxiliary Relay Box #2
2 Door W/o Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7908
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Relay Module > Page 7909
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7912
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7913
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7914
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7915
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7916
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7917
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7918
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7919
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7920
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7921
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Application and ID > Passenger Compartment Fuse Panel /
Central Junction Box (CJB) > Page 7922
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7927
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7928
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7929
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7930
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7931
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7932
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7933
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7934
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7935
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7936
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7937
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Relay Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Relay Module > Page 7940
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Relay Module > Page 7941
Relay Box: Diagrams Auxiliary Relay Box #2
2 Door W/o Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Relay Module > Page 7942
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Diagrams > Relay Module > Page 7943
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7946
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7947
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7948
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7949
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7950
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7951
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7952
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7953
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7954
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7955
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information >
Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 7956
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips
Technical Service Bulletin # 05-18-7 Date: 050922
Electrical - Wiring Soldering/Crimping Service Tips
TSB 05-18-7
09/22/05
WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS
FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006
Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005
Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005
Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006
F-650, F-750 2006 Low Cab Forward
LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood
2003-2005 Aviator 2006 Mark LT
MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego
2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model
years.
ISSUE Wire harness repairs are supported through the availability of individual components such
as:
^ Wire terminals with machine crimped pigtails
^ Hard shell connectors
^ Dual wall heat shrink tubing
^ Complete, loaded, wiring pigtail kits
Some of the available tools and service parts that are helpful when performing wiring harness
repairs are:
^ Motorcraft Wiring Pigtail Catalog (see website for more information)
^ Rotunda Wire Splice Tool kit 164-R5903
^ General Wire Terminal Repair Kit (order through Ford Component Sales)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7961
Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15
web site. To access on PTS:
^ Select the year/model of the vehicle on the P15 home page
^ Select the wiring tab
^ Select the link to the pigtail or terminal repair kit at the top right of screen.
Additional service information contained in this TSB detailing wire folding, soldering, and crimping
techniques may be helpful.
ACTION
REPAIR VS REPLACEMENT
The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell
connectors when available. The only exceptions to this procedure are when:
^ The repair cost exceeds the cost to replace the wiring harness
^ There are no component parts released to service the wiring harness
RESTRAINTS RELATED WIRING REPAIRS
If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair
them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford
Motor Company publication.
If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401,
14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified
in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with
white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits
with gold plated terminals are also available in the parts catalog.
Disclaimer
Service Tips
Refer to applicable model year wiring diagrams for circuit information.
Twisted Wire Circuits
For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51
mm) Twist the repaired wires in the same direction and with the same general twist rate as the
original wiring. Reapply the shielding on shielded circuits.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7962
Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2).
Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed
(Figure 2). Silicone must not be used.
Excess wire from the harness can be folded back on itself to maintain the harness length.
Reapply any convolute and tape that was removed to make the repair.
For 16 AGW and Smaller Diameter Wire
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7963
1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2,
taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled
at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut
off the end and re-strip.
2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced.
Twist wires together. Solder wires together (Figure 4).
NOTE
USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER
FOR WIRE REPAIR.
3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond.
NOTE
WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7964
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7965
4. Evenly position heat shrink tubing over wire repair (Figure 5).
NOTE
OVERLAP TUBING ON BOTH WIRES.
5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt
appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the
hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between
the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the
solder point (Figure 5).
For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs)
1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs
can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire
is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during
stripping, cut off the end and re-strip.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7966
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7967
NOTE
THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN
HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE
FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP
LENGTHS AND FOLDING TECHNIQUES.
2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4
mm) away from stripped end (Figure 6).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7968
3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or
equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice
(Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles
together until the ratchet releases, then allow the jaws of the tool to open fully.
4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to
place the brazed seam of the butt splice toward the indenter (Figure 8).
5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages
sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the
butt splice.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 7969
6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt
splice (Figure 8).
7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool
handles to open, then remove crimped butt splice.
8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping
chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool
around.
9. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly
off center, but not off the end of the buff splice (Figure 9-a).
b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of
buff splice (Figure 9-b).
c. Wire is visible through inspection hole of splices (Figure 9-c).
10. Evenly position heat shrink tubing over wire repair (Figure 5).
NOTE
OVERLAP TUBING ON BOTH WIRES.
11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt
appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the
hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between
the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the
solder point (Figure 5).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Locations > Auxilirary Relay Box #1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Locations > Auxilirary Relay Box #1 > Page 7978
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Locations > Auxilirary Relay Box #1 > Page 7979
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Locations > Auxilirary Relay Box #1 > Page 7980
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Locations > Auxilirary Relay Box #1 > Page 7981
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions
Electrical Accessory Panel: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7984
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7985
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7986
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7987
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7988
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7989
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7990
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7991
Electrical Accessory Panel: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7992
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7993
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Diagrams > Diagram Information and Instructions > Page 7995
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Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7996
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Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information >
Diagrams > Diagram Information and Instructions > Page 7997
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8006
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8007
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8008
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8009
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8010
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8011
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8012
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > Customer Interest for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio System Whining/Buzzing Noise From Speakers > Page 8013
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers
Technical Service Bulletin # 02-16-4 Date: 020819
Audio System - Whining/Buzzing Noise From Speakers
Article No. 02-16-4
08/19/02
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO-WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO-WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994 TEMPO 1990-1997 ESCORT, PROBE, THUNDERBIRD 1990-1998 MUSTANG
1990-1999 TAURUS 1990-2002 CROWN VICTORIA 1997-1999 CONTOUR 2001 TAURUS 1990
BRONCO II 1990-1996 BRONCO 1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD 1990-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER
1995-2002 WINDSTAR 1997-2003 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002
EXCURSION, EXPLORER SPORT TRAC, EXPLORER SPORT 2001-2002 ESCAPE
LINCOLN: 1990-1992 MARK VII 1990-1994 CONTINENTAL 1990-2002 TOWN CAR 1998-2003
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1990-1994 TOPAZ 1990-1997 COUGAR 1990-1999 SABLE 1990-2002 GRAND
MARQUIS 1991-1997 TRACER 1997-1999 MYSTIQUE 2001 SABLE 1993-2002 VILLAGER
1997-2002 MOUNTAINEER
TSB 01-7-3 is being republished in its entirety to update the model year coverage and vehicle line
coverage.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 8019
NOTE
IF THE VEHICLE HAS AN ELECTRONIC RETURNLESS FUEL SYSTEM, DO NOT INSTALL A
RFI FILTER INLINE TO THE FUEL PUMP . ONLY VEHICLES WITH MECHANICAL
RETURNLESS FUEL SYSTEMS (PRESSURE REGULATOR IN THE TANK), OR SYSTEMS
WITH THE PRESSURE REGULATOR ON THE FUEL RAIL SHOULD BE APPROVED FOR THE
RFI FILTER INSTALLATION.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-7-3
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
021604AA Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1997 Thunderbird/Cougar
021604BA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1999 And 2001 Taurus/Sable
021604CA Diagnose And Install RFI 1.2 Hrs.
Filter 1992-1997 Crown Victoria/Grand Marquis/Town Car
021604CB Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1991 Crown Victoria/Grand Marquis/Town Car
021604CC Diagnose And Install RFI 2.2 Hrs.
Filter 1998-2002 Crown Victoria/Grand Marquis
021604DA Diagnose And Install RFI 1.9 Hrs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 8020
Filter 1998-2002 Town Car
021604EA Diagnose And Install RFI 1.7 Hrs.
Filter 1990-1998 Mustang
021604FA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-1998 Mustang
021604GA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1994 Continental
021604HA Diagnose And Install RFI 1.6 Hrs.
Filter 1990 Escort
021604IA Diagnose And Install RFI 0.8 Hr.
Filter 1991-1996 Escort Tracer
021604IB Diagnose And Install RFI 1.6 Hrs.
Filter 1997 Escort/Tracer
021604JA Diagnose And Install RFI 0.8 Hr.
Filter 1997 Contour/Mystique
021604JB Diagnose And Install RFI 1.8 Hrs.
Filter 1998-1999 Contour/Mystique
021604KA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1992 Mark VII
021604LA Diagnose And Install RFI 0.8 Hr.
Filter 1990-1992 Probe
021604LB Diagnose And Install RFI 1.8 Hrs.
Filter 1993-1997 Probe
021604MA Diagnose And Install RFI 1.6 Hrs.
Filter 1990-2002 Econoline Single Fuel Tank
021604MB Diagnose And Install RFI 2.6 Hrs.
Filter 1990-1991 Econoline Both Fuel Tanks
021604NA Diagnose And Install RFI 2.0 Hrs.
Filter 1990-1996 Bronco
0216040A Diagnose And Install RFI 1.8 Hrs.
Filter 1991-1994 Explorer
0216040B Diagnose And Install RFI 1.5 Hrs.
Filter 1995-2002 Explorer
021604PA Diagnose And Install RFI 1.5 Hrs.
Filter 1997-2002 Mountaineer
0216040A Diagnose And Install RFI 1.4 Hrs.
Filter 1995-2002 Windstar
021604RA Diagnose And Install RFI 1.9 Hrs.
Filter 1993-2002 Villager
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 8021
021604SA Diagnose And Install RFI 1.7 Hrs.
Filter 1997-2003 Expedition/Navigator
021604TA Diagnose And Install RFI 1.3 Hrs.
Filter 1990-1997 Ranger Standard Cab
021604TB Diagnose And Install RFI 1.8 Hrs.
Filter 1990-1997 Ranger Super Cab
021604TC Diagnose And Install RFI 1.8 Hrs.
Filter 1998-2002 Ranger 4X4
021604TD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 Ranger 4X2
021604UA Diagnose And Install RFI 1.5 Hrs.
Filter 1990-1997 Aerostar
021604VA Diagnose And Install RFI 1.9 Hrs.
Filter 1990 Bronco II
021604WA Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Rear
021604WB Diagnose And Install RFI 1.4 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Front
021604WC Diagnose And Install RFI 2.1 Hrs.
Filter 1990-1996 F-150/250/350/Super Duty And 1997 F-350/Superduty Both Tanks
021604WD Diagnose And Install RFI 1.6 Hrs.
Filter 1998-2002 F-150
021604XA Diagnose And Install RFI 1.6 Hrs.
Filter 2000-2002 Excursion
021604XB Diagnose And Install RFI 1.6 Hrs.
Filter 1999-2002 Super Duty F-Series: Front Tank
021604XC Diagnose And Install RFI 1.5 Hrs.
Filter 1999-2002 Super Duty F-Series: Rear Tank
021604XD Diagnose And Install RFI 2.7 Hrs.
Filter 1999-2002 Super Duty F-Series: Both Tanks
021604YA Diagnose And Install RFI 0.8 Hr.
Filter 2001-2002 Escape
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 8022
021604ZA Diagnose And Install RFI 1.9 Hrs.
Filter 2002 Blackwood
DEALER CODING
CONDITION
BASIC PART NO. CODE
18B925 42
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Service Procedure
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 8023
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-AA) over the solder connections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 8024
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 8025
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over solder connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Electronic Noise Suppressor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Electronic Noise Suppressor: > 02-16-4 > Aug > 02 > Audio
System - Whining/Buzzing Noise From Speakers > Page 8026
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PER
THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2 ")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and Vacuum Troubleshooting Manual (EVTM) (or other service
literature) for the location of the fuel pump ground. If ground is more than 0.9m (3 ') from the tank,
cut wire and ground fuel pump end within 0.9m (3 ') of the tank to prevent ground wire from acting
as an antenna. Be sure ground is secure and protected from corrosion since it is the operating
ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop Manual.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8031
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8032
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8033
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8034
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8035
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8036
Fuse: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8037
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8038
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8039
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8040
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8041
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions
Fuse: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8044
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8045
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8046
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8047
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8048
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8049
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8050
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8051
Fuse: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8052
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8053
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8054
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8056
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Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Diagrams > Diagram
Information and Instructions > Page 8057
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8060
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8061
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8062
Fuse 1 - 10
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Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8063
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8064
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8065
Fuse: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
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Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8066
Fuses
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Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8067
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8068
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8069
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8070
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8075
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8076
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8077
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8078
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8079
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8080
Fuse Block: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8081
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8082
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8083
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Compartment Fuse Panel / Central Junction Box (CJB) > Page 8084
Fuses
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Compartment Fuse Panel / Central Junction Box (CJB) > Page 8085
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions
Fuse Block: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 8088
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Information and Instructions > Page 8089
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 8090
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 8091
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 8092
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 8093
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Information and Instructions > Page 8095
Fuse Block: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Information and Instructions > Page 8096
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Information and Instructions > Page 8097
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 8099
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 8100
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram
Information and Instructions > Page 8101
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Fuse Block: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8104
Fuse 1 - 18
Fuse 19 - 36
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8105
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8106
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8107
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8108
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8109
Fuse Block: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8110
Fuses
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8111
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8112
Battery Junction Box (BJB) / Power Distribution Box
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8113
Fuses
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Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8114
Fuses
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Ford Workshop Manuals > Power and Ground Distribution > Ground Strap > Component Information > Specifications
Ground Strap: Specifications
Intake Manifold Ground Strap Nut
...................................................................................................................................................... 7-9
Nm (62-80 Lb-In) Battery Ground Cable Screw
..............................................................................................................................................................
7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt
.............................................................................................................................................. 8.9-12.1
Nm (79-107 Lb-In)
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Page 8118
Ground Strap: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the nut and washer (A) attaching the ground strap (B) to the stud.
3. Remove the fastener from the rear of the right cylinder head and ensure that the mounting
surfaces of the studs are free of dirt and corrosion.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Page 8119
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Micro ISO Relay > Component Information > Testing and
Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Mini ISO Relay > Component Information > Testing and
Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8130
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8131
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8132
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8133
Multiple Junction Connector: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8134
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8135
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8136
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8137
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8138
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8139
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8140
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8141
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8142
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8143
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8144
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8145
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8146
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8147
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8148
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8149
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8150
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8151
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8152
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8153
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8154
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8155
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8156
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8157
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8158
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8159
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8160
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8161
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8162
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8163
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > C113 > Page 8164
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
Power Distribution Relay: Locations
Trailer Tow Park Lamp Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 8168
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 8169
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information > Locations
> Page 8170
Power Distribution Relay: Testing and Inspection
Trailer Tow Park Lamp Relay Test
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Micro
ISO Relay > Component Information > Testing and Inspection
Micro ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Mini
ISO Relay > Component Information > Testing and Inspection
Mini ISO Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
Power Distribution Relay: Locations
Trailer Tow Park Lamp Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 8181
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 8182
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations > Page 8183
Power Distribution Relay: Testing and Inspection
Trailer Tow Park Lamp Relay Test
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8188
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8189
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8190
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8191
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8192
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8193
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8194
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8195
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8196
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8197
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Locations > Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page
8198
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Relay Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Relay Module > Page 8201
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Relay Module > Page 8202
Relay Box: Diagrams Auxiliary Relay Box #2
2 Door W/o Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Relay Module > Page 8203
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Diagrams > Relay Module > Page 8204
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8207
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8208
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8209
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8210
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8211
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8212
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8213
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8214
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8215
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8216
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay
Box > Component Information > Application and ID > Passenger Compartment Fuse Panel / Central Junction Box (CJB) >
Page 8217
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Locations Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8222
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8223
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8224
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8225
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8226
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8227
Relay Box: Locations Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8228
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8229
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8230
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8231
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Passenger
Compartment Fuse Panel / Central Junction Box (CJB) > Page 8232
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay
Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay
Module > Page 8235
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay
Module > Page 8236
Relay Box: Diagrams Auxiliary Relay Box #2
2 Door W/o Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay
Module > Page 8237
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Relay
Module > Page 8238
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Relay Box: Application and ID Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8241
Fuse 1 - 18
Fuse 19 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8242
Passenger Compartment Fuse Panel / Central Junction Box (CJB)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8243
Fuse 1 - 10
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8244
Fuse 11 - 31
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8245
Fuse 32 - 36
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8246
Relay Box: Application and ID Battery Junction Box (BJB) / Power Distribution Box
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8247
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8248
Relays
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8249
Battery Junction Box (BJB) / Power Distribution Box
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8250
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID >
Passenger Compartment Fuse Panel / Central Junction Box (CJB) > Page 8251
Fuses
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips
Technical Service Bulletin # 05-18-7 Date: 050922
Electrical - Wiring Soldering/Crimping Service Tips
TSB 05-18-7
09/22/05
WIRING - SOLDERING AND CRIMPING REPAIRS - SERVICE TIPS
FORD: 2000-2006 Crown Victoria, Focus, Mustang, Taurus 2002-2005 Thunderbird 2005-2006
Five Hundred, Ford GT, Freestyle 2006 Fusion 2000-2003 Explorer Sport, Windstar 2000-2005
Excursion 2000-2006 E-Series, Expedition, Explorer, F-150, F-Super Duty, Ranger 2001-2005
Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape Hybrid 2000-2006
F-650, F-750 2006 Low Cab Forward
LINCOLN: 2000-2006 LS, Town Car 2006 Zephyr 2000-2006 Navigator 2002-2003 Blackwood
2003-2005 Aviator 2006 Mark LT
MERCURY: 2000-2002 Cougar 2000-2005 Sable 2000-2006 Grand Marquis 2005-2006 Montego
2006 Milan 2000-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner 2006 Mariner Hybrid
This article supersedes TSB 03-11-6 to update the service procedure, vehicle lines and model
years.
ISSUE Wire harness repairs are supported through the availability of individual components such
as:
^ Wire terminals with machine crimped pigtails
^ Hard shell connectors
^ Dual wall heat shrink tubing
^ Complete, loaded, wiring pigtail kits
Some of the available tools and service parts that are helpful when performing wiring harness
repairs are:
^ Motorcraft Wiring Pigtail Catalog (see website for more information)
^ Rotunda Wire Splice Tool kit 164-R5903
^ General Wire Terminal Repair Kit (order through Ford Component Sales)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8256
Information on the pigtail and terminal repair kits can also be accessed by technicians via the P15
web site. To access on PTS:
^ Select the year/model of the vehicle on the P15 home page
^ Select the wiring tab
^ Select the link to the pigtail or terminal repair kit at the top right of screen.
Additional service information contained in this TSB detailing wire folding, soldering, and crimping
techniques may be helpful.
ACTION
REPAIR VS REPLACEMENT
The approved procedure is to repair wiring harnesses with pigtail kits, wire terminals, or hard shell
connectors when available. The only exceptions to this procedure are when:
^ The repair cost exceeds the cost to replace the wiring harness
^ There are no component parts released to service the wiring harness
RESTRAINTS RELATED WIRING REPAIRS
If restraints connectors or wiring circuits are contained in a stand-alone harness, do not repair
them; replace the restraints harness unless directed to repair the circuit by a TSB or other Ford
Motor Company publication.
If restraints connectors or wiring circuits are contained in the main vehicle wiring harnesses (14401,
14A005, etc.), they should be repaired using the solder and heat-shrink repair procedure specified
in this TSB. The General Wire Terminal Repair Kit contains gold plated terminated pigtails (with
white insulation) and dual wall heat shrink tubing to perform these repairs. Loaded wiring pigtail kits
with gold plated terminals are also available in the parts catalog.
Disclaimer
Service Tips
Refer to applicable model year wiring diagrams for circuit information.
Twisted Wire Circuits
For "Twisted Wire" circuit repair (Figure 1), the twisting must not be disrupted for more than 2" (51
mm) Twist the repaired wires in the same direction and with the same general twist rate as the
original wiring. Reapply the shielding on shielded circuits.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8257
Stagger the repairs to minimize harness diameter and maintain harness length (Figure 2).
Any leads that are not going to be used need to be sealed with dual wall heat shrink and stowed
(Figure 2). Silicone must not be used.
Excess wire from the harness can be folded back on itself to maintain the harness length.
Reapply any convolute and tape that was removed to make the repair.
For 16 AGW and Smaller Diameter Wire
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8258
1. Strip 1-1/2" (37.2 mm) of insulation from Wire # 1 and 3/4" (19.5 mm) of insulation from Wire # 2,
taking care not to nick or cut wire strands (Figure 3). Pull wire straight from stripper. If wire is pulled
at an angle, wire strands may be cut off. If more than one (1) strand is cut off during stripping, cut
off the end and re-strip.
2. Install heat shrink tubing at least 1" (26 mm) away from one of the stripped ends being spliced.
Twist wires together. Solder wires together (Figure 4).
NOTE
USE ROSIN CORE MILDLY ACTIVATED (RMS) SOLDER. DO NOT USE ACID CORE SOLDER
FOR WIRE REPAIR.
3. Bend Wire # 1 back in a straight line for sealing (Figure 4). Inspect solder joint bond.
NOTE
WAIT FOR SOLDER TO COOL BEFORE MOVING WIRES.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8259
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8260
4. Evenly position heat shrink tubing over wire repair (Figure 5).
NOTE
OVERLAP TUBING ON BOTH WIRES.
5. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt
appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the
hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between
the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the
solder point (Figure 5).
For 14 AGW and Larger Diameter Wire (Excluding Restraints Wiring Repairs)
1. Strip 1/4" (6.35 mm) of insulation from pigtail wire end once the wire lengths are sized so repairs
can be staggered. Take care not to nick or cut wire strands. Pull wire straight from stripper. If wire
is pulled at an angle, wire strands may be cut off. If more than one (1) strand is cut off during
stripping, cut off the end and re-strip.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8261
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8262
NOTE
THE STRIP LENGTH WILL VARY DEPENDING ON THE BUTT SPLICE AND WIRE IN
HARNESS. LONGER STRIP LENGTHS ARE REQUIRED WHEN THE WIRE NEEDS TO BE
FOLDED TO MATE WITH THE BUTT SPLICE. REFER TO FIGURE 10 CHART FOR STRIP
LENGTHS AND FOLDING TECHNIQUES.
2. Slide heat shrink tubing onto one (1) of the wire ends to be crimped, must be at least 1" (25.4
mm) away from stripped end (Figure 6).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8263
3. Identify the appropriate crimping chamber of the Rotunda 164-R5901 Pro-Crimper (or
equivalent) by matching the wire size on the dies with the wire size stamped on the butt splice
(Figure 7). Hold the crimping tool so the identified wire sizes are facing you. Squeeze tool handles
together until the ratchet releases, then allow the jaws of the tool to open fully.
4. Center one (1) end of the butt splice on the appropriate crimping chamber. If visible, be sure to
place the brazed seam of the butt splice toward the indenter (Figure 8).
5. Hold the butt splice in place and squeeze the tool handles together until the ratchet engages
sufficiently to hold the butt splice in position (typically one (1) or two (2) clicks). DO NOT deform the
butt splice.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service
Bulletins > Electrical - Wiring Soldering/Crimping Service Tips > Page 8264
6. Insert stripped wire into the buff splice, making sure the insulation on wire does not enter the butt
splice (Figure 8).
7. Holding the wire in place, squeeze tool handles together until ratchet releases. Allow tool
handles to open, then remove crimped butt splice.
8. To crimp the other half of the splice, reposition the un-crimped wire barrel in the same crimping
chamber, and repeat Steps 3-8. If splice cannot be turned for crimping the other half, turn the tool
around.
9. Check for acceptable crimp.
a. Crimp should be centered on each end of the butt splice. It is acceptable for crimp to be slightly
off center, but not off the end of the buff splice (Figure 9-a).
b. Wire insulation does not enter butt splice. Wire is flush with or extends slightly beyond end of
buff splice (Figure 9-b).
c. Wire is visible through inspection hole of splices (Figure 9-c).
10. Evenly position heat shrink tubing over wire repair (Figure 5).
NOTE
OVERLAP TUBING ON BOTH WIRES.
11. Use a shielded heat gun to heat the entire length of the heat shrink tubing until the hot melt
appears from both ends of the tubing. Durability of a heat shrink tubing splice is dependent on the
hot melt that will appear from both ends of the tube. The hot melt forms an adhesive seal between
the wire insulation and the heat shrink tubing, which prevents air and moisture from entering the
solder point (Figure 5).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Alignment Procedure Revision
Alignment: Technical Service Bulletins Steering/Suspension - Alignment Procedure Revision
TSB 04-24-19
12/13/04
REVISED PROCEDURE FOR ADJUSTING ALIGNMENT ON ALL SUSPENSIONS - NEW RIGHT
HAND UPPER CONTROL ARM DESIGN FOR TORSION BAR FRONT SUSPENSIONS
FORD: 1998-2001 Explorer 1998-2003 Ranger 2000-2003 Explorer Sport 2001-2003 Explorer
Sport Trac
ISSUE The cam bolt and nut kit that was used for adjusting caster and camber on all torsion bar
and coil spring front suspensions has been discontinued. If the caster and camber settings need to
be adjusted, a washer must now be installed.
The right hand upper control arm design changed from a two piece design to a single piece design
during the 2003 model year. The single piece design is now the only version of the upper control
arm available for service of prior model year Rangers.
ACTION Use the following Camber And Caster Adjustment procedure when either camber or
caster need to be adjusted on any suspension, or if only a caster split adjustment is needed on a
vehicle equipped with single piece upper control arm.
Use the following Caster Split Adjustment - Two Piece Right Hand Upper Control Arm procedure if
only a caster split adjustment is needed on a vehicle equipped with a two piece upper control arm.
SERVICE PROCEDURE
CAMBER AND CASTER ADJUSTMENT
NOTE
THE UPPER CONTROL ARM-TO-FRAME MOUNTING BOLTS HAVE SET SHIMS THAT MUST
BE REPLACED WITH WASHERS TO ALLOW FOR ADJUSTMENT OF THE ARM IN THE FRAME
SLOT. THE VEHICLE SHOULD BE SUPPORTED BY THE LOWER CONTROL ARM TO EASE
MOVEMENT OF THE UPPER ARM IN THE SLOT.
1. Remove and discard the upper control arm-to-frame nuts and shims (Figure 1).
2. Install new washers (W705040-5900) and nuts (N805480-5427). Tighten the nuts so there is
tension, but the upper control arm can be moved for the alignment adjustment.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Steering/Suspension - Alignment Procedure Revision > Page 8270
3. To adjust caster and camber refer to the chart. Adjustments that require moving the front and
rear of the upper control arm should be made equally.
4. Torque the upper control arm-to-frame nuts to 98 lb.ft (133 N.m).
5. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for
information.
CASTER SPLIT ADJUSTMENT - TWO PIECE RIGHT HAND UPPER CONTROL ARM
1. To decrease the right hand caster, loosen the ball joint adjustment nuts (Figure 2) and move the
ball joint forward.
2. To increase the right hand caster, loosen the ball joint adjustment nuts and move the ball joint
rearward.
3. Torque the ball joint adjustment nuts to 129 lb.ft (175 N.m).
4. Check and if necessary adjust the front toe. Refer to the appropriate Workshop Manual for
information.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
3084 07
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins >
Page 8271
Alignment: Specifications
Caster LH 4.2 - 1.0 deg
0 deg. Frame Angle (If vehicle is higher in the rear, add
the frame angle to the measured caster. If vehicle is
lower in the rear, subtract the frame angle from the
measured caster. Compare the total to the specification.)
RH 4.2 - 1.0 deg
Total/Split -0.7 +/- 0.5 deg
Camber LH -0.5 +/- 0.5 deg
RH -0.5 +/- 0.5 deg
Total/Split 0 +/- 0.7 deg
Toe 0.12 +/- 0.25 deg
@ Curb Ride Height (positive value is toe-in, negative
value is toe-out)
Wheel Track 0.02 in
Dogtracking 1.18 in
maximum (centerline of front tires compared to centerline
of rear tires)
Clear Vision -2.4 +/- 3.0 deg
(negative value is counterclockwise)
Front Ride Height New Vehicles With less than 500 miles 4.4 +/- 0.4 in
Original Parts 4.0 +/- 0.4 in
Replacement Parts 4.4 +/- 0.1 in
Rear Ride Height 4 Door Vehicles 5 - 5.8 in
2 Door Vehicles 4.3 - 4.8 in
Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in
Upper Ball Joint Maximum 1/32 in
Vehicle Lean Front Wheel Opening Maximum 0.6 in
Side to Side Height Differences
Rear Wheel Opening Maximum 0.78 in
Torque Specifications Caster Set Jam Nuts 129 ft lb
Front Suspension Upper Arm Cam Nuts 98 ft lb
Toe Set Jam Nuts 59 ft lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber
Alignment: Description and Operation Camber
Negative and Positive Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 8274
Alignment: Description and Operation Caster
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 8275
Alignment: Description and Operation Dogtracking
Dogtracking
Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned
roads can give the illusion of dogtracking.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 8276
Alignment: Description and Operation Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the
steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 8277
Alignment: Description and Operation
Camber
Negative and Positive Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or
negative and has a direct effect on tire wear.
Caster
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed
from the side. The caster specifications will give the vehicle the best directional stability
characteristics when loaded and driven. The caster setting is not related to tire wear.
Dogtracking
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 8278
Dogtracking
Dogtracking is the condition in which the rear axle is not square to the chassis. Heavily crowned
roads can give the illusion of dogtracking.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep
the vehicle going straight. Drift describes what a vehicle with this condition does with hands off the
steering wheel. ^
A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
^ Drift/pull may be induced by conditions external to the vehicle (i.e., wind, road camber).
General Information
Caster and camber are adjusted by means of eccentric cams on the upper control arm mounting
bolts. Toe is adjusted by the use of the front wheel spindle tie-rod.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various
road surfaces and observed by the driver as small rotational oscillations of the steering wheel.
Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as
the wheel is rocked slowly left and right within very small turns around center or straight-ahead
(under 20° of steering wheel turn). Efforts may be said to be "flat on center." ^
Under 20° of turn, most of the turning effort that builds up comes from the mesh of gear teeth in the
steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from the
self-aligning forces at the road wheel or tire patch.
^ In the diagnosis of a readability problem, it is important to understand the difference between
wander and poor groove feel.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe the poor return of the steering wheel to
center after a turn or the steering correction is completed.
Ride Height
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 8279
Front Ride Height Measurement
Rear Ride Height Measurement
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel
resulting from large, side-to-side (lateral) tire/wheel movements. Shimmy is usually experienced
near 64 km/h (40 mph), and can begin or be amplified when the tire contacts pot holes or
irregularities in the road surface.
Toe
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Camber > Page 8280
Positive Toe (Toe In)
Positive Toe (Toe In)
Negative Toe (Toe Out)
Negative Toe (Toe Out)
The vehicle toe setting: ^
affects tire wear and directional stability.
^ must be checked after adding aftermarket equipment, such as a snowplow or body.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel
corrections to maintain a straight path down a level road.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment
Alignment: Service and Repair Camber and Caster Adjustment
1. Remove the nuts and alignment plates.
2. Install the cams and the nuts.
3. Note: A pry bar can be used between the front suspension arm bushing joint and the frame
pocket to aid in moving the farm.
To increase the LF caster and camber, use the following steps. 1
To increase caster, move the front of the front suspension arm bushing joint outboard and move
the rear of the front suspension arm bushing joint inboard.
2 To increase camber, move the front suspension arm bushing joint outboard equally.
4. To decrease the LF caster and camber, use the following steps.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 8283
1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move
the rear of the front suspension arm bushing joint outboard.
2 To decrease camber, move the front suspension arm bushing joint inboard equally.
5. Tighten the nuts.
6. Note: A pry bar can be used between the front suspension arm bushing joint and the frame
pocket to aid in moving the arm.
To increase RF caster and camber, use the following steps. 1
To increase caster, move the front of the front suspension arm bushing joint outboard and move
the rear of the front suspension arm bushing joint inboard.
2 To increase camber, move the front suspension arm bushing joint outboard equally.
7. To decrease the RF caster and camber, use the following steps.
1 To decrease caster, move the front of the front suspension arm bushing joint inboard and move
the rear of the front suspension arm bushing joint outboard.
2 To decrease camber, move the front suspension arm bushing joint inboard equally.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 8284
8. Increase the caster split.
1 Loosen the nuts.
2 Adjust the caster set bolts forward.
9. Decrease the caster split.
1 Loosen the nuts.
2 Adjust the caster set bolts rearward.
10. Tighten the nuts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 8285
Alignment: Service and Repair Ride Height
Ride Height - Front Suspension
1. Drive the vehicle onto a drive-on lift. 2. Jounce the vehicle's front and rear suspension to
normalize the vehicle static ride height.
3. Measure the distance between the center line of the front suspension lower arm bushing bolt
and the lift. Record the measurement.
4. Measure the distance between the front wheel spindle (lowest point) and the lift. Record the
measurement.
5. Determine ride height.
^ Subtract measurement
1 from measurement
2. This is the ride height.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 8286
6. Note: The torsion bar adjusting bolt is coated with adhesive that wears; off after disassembly. If
the torsion bar system is ever disassembled or the
torsion bar adjusting bolt is ever removed, use a new torsion bar adjusting bolt when
re-assembling.
Adjust the torsion bars (height) as necessary by tightening or loosening the torsion bar adjusting
bolt. ^
Tighten the torsion bar adjusting bolt to increase the torque or raise the height.
^ Loosen the torsion bar adjusting bolt to decrease the torque or lower the height.
Ride Height - Vehicle Dynamic Suspension
Special Service Tool(s)
1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT
screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle
to its
lowest attainable height: ^
REAR FILL (rear fill solenoid).
^ GATE VALVE (gate solenoid).
^ VENT (vent solenoid).
3. Close all doors including the liftgate and liftgate window. 4. Reopen any door (to ensure that the
height will not change until the internal electronic calibration is complete). 5. Park the vehicle on a
flat surface. 6. From the function menu, quickly select RIDE HEIGHT CALIBRATION. 7. Note the
warning on the scan tool screen and follow the directions. 8. Lower the vehicle and clear all stored
Diagnostic Trouble Codes (DTCs).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 8287
Alignment: Service and Repair Toe Adjustment
1. Start the engine and center the steering wheel. 2. Turn the engine off, and hold the steering
wheel in the "straight forward" position by attaching a rigid link from the steering wheel to the brake
pedal.
3. Check the toe settings; follow the manufacturer's instructions.
4. Note: Do not allow the steering gear bellows to twist when the front wheel spindle tie-rod (3280)
is rotated.
Remove the clamps.
5. Loosen the nuts.
^ Clean and lubricate the nut(s) and front wheel spindle tie-rod threads.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber and
Caster Adjustment > Page 8288
6. Rotate the front wheel spindle tie-rods.
7. Tighten the nuts.
8. Install the clamps. 9. Recheck the toe settings; follow the manufacturer's instructions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8294
Compressor/Pump Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications
Suspension Control Module: Specifications
Air Suspension Control Module Mounting Screws 18 - 27 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8298
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8299
Suspension Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8300
Suspension Control Module: Service and Repair
Removal
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Note: Ride heights must be reset for the air suspension module whenever the air suspension
module is replaced.
Disconnect the battery negative ground cable.
2. Remove the center instrument panel finish panel.
1 Remove the center instrument panel finish panel screws.
2 Disconnect the electrical connectors and remove the center panel finish panel.
3. Remove the air suspension control module.
1 Remove the air suspension control module screws.
2 Slide the air suspension control module down and out of the support bracket.
4. Disconnect the air suspension control module electrical connectors and remove the air
suspension control module.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and
Modules - Suspension > Suspension Control Module > Component Information > Specifications > Page 8301
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
Note: When installing a new air suspension control module, ride height adjustment must be
performed. Ride Height Adjustments
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Component
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Ride Height Sensor, Suspension Control > Component Information > Locations > Page 8308
Ride Height Sensor: Service and Repair
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the rear jack storage area. Failure to do so may result in unexpected
inflation or deflation of the air springs which may result in shifting of the vehicle during these
operations.
1. Raise and support the vehicle. 2. Remove the spare tire
3. Disconnect the height sensor electrical connector and remove the electrical connector harness
from the frame and apron to separate the push-in
fasteners
4. Release the upper and lower spring clip and pull the sensor from the ball studs.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and
Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair
Suspension Mode Switch: Service and Repair
Removal
1. Remove the jack storage access cover.
2. Remove the retaining screw and air suspension switch bracket.
3. Remove the air suspension switch.
1 Disconnect the electrical connector.
2 Press the retaining clips and remove the air suspension switch from the bracket.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Special Service Tool(s)
Removal
1. Remove the wheel hub.
2. Remove the torsion bar cover plate.
1 Remove the retaining bolts.
2 Remove the torsion bar cover plate.
3. Note: Before relieving the torsion bar tensions, measure and record the measurement of the
torsion bar adjustment bolt. This measurement will be
used as the preset depth for the new torsion bar adjustment bolt during installation.
Measure and record the length where indicated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 8316
4. Relieve the torsion bar tension.
1 Position the torsion bar tool and the adapters.
2 Tighten the torsion bar tool until the torsion bar adjuster lifts off of the adjustment bolt.
5. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive and must be replaced if it
is backed off or removed. Failure to do so can
cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment.
Remove the torsion, bar adjustment bolt and nut.
6. Loosen the torsion bar adjustment tool until the tension is off the torsion bar.
7. Reposition the anti-lock sensor wire.
1 Remove the front brake anti-lock sensor wire bracket bolt.
2 Reposition the anti-lock sensor wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 8317
8. CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can
cause damage to the front axle shaft.
Suspend the front axle shaft with wire.
9. Remove the tie rod end castellated nut.
1 Remove the tie rod end cotter pin.
2 Remove the tie rod end castellated nut.
10. Use the Pitman Arm Puller to separate the tie rod end.
^ Separate the tie rod end from the front wheel knuckle.
11. Remove the lower ball joint castellated nut.
1 Remove the lower ball joint cotter pin.
2 Remove the lower ball joint castellated nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 8318
12. Use the Pitman Arm Puller to separate the front wheel knuckle front the front suspension lower
arm.
13. Remove the pinch bolt. 14. Remove the front wheel knuckle.
Installation
1. Install the front wheel knuckle pinch bolt and nut.
1 Position the front wheel knuckle on the front suspension upper arm.
2 Install the pinch bolt and nut.
2. Install the front suspension arm lower ball joint castellated nut.
1 Position the front wheel knuckle,
2 Install the castellated nut.
3 Install a new cotter pin.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 8319
3. Install the tie rod end castellated nut.
1 Position the tie rod end.
2 Install the tie rod end castellated nut.
3 Install a new cotter pin.
4. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive and must be replaced if it
is backed off or removed. Failure to do so can
cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment.
Preload the torsion bar. 1
Tighten the torsion bar tool until the new adjustment bolt and nut can be installed.
2 Turn the adjustment bolt until preliminary adjustment marks are aligned.
5. Remove the torsion bar tool and adapters.
6. Install the torsion bar cover plate.
1 Position the torsion bar cover plate.
2 Install the retaining bolts.
7. Install the wheel hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Page 8320
8. Install the anti-lock sensor wire bracket bolt.
1 Position the anti-lock sensor wire.
2 Install the bolt.
9. Adjust the ride height.
10. Check the alignment.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair
Power Steering Bleeding: Service and Repair
Special Tools
Special Service Tool(s)
CAUTION: If the air is not purged from the power steering system correctly, premature power
steering pump failure could result. The condition can occur on pre-delivery vehicles with evidence
of aerated fluid or on vehicles that have had steering component repairs.
1. Note: A whine heard from the power steering pump may be caused by air in the system. The
power steering purge procedure must be performed
prior to any component repair for which power steering noise complaints arc accompanied by
evidence of aerated fluid.
Remove the reservoir cap. Check the fluid. ^
Use Motorcraft MERCON Multipurpose ATF XT-2-QDX or MERCON equivalent.
2. Tightly insert the stopper of the vacuum pump into the reservoir. 3. Start the vehicle.
4. Apply maximum vacuum and maintain it for a minimum of three minutes with the engine speed
set at idle. 5. Release the vacuum and remove the vacuum pump.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System
Information > Service and Repair > Page 8325
6. CAUTION: Do not overfill the power steeling pump reservoir.
Fill the reservoir. ^
Use Motorcraft MERCON Multipurpose ATF XT-2-QDX or MERCON equivalent.
7. Reinstall the vacuum pump. Apply and maintain maximum vacuum.
8. CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds
at a time. Damage to the power steering pump
could occur.
Cycle the steering wheel fully to the left and right every 30 seconds for approximately five minutes.
9. Stop the engine, release the vacuum, and remove the vacuum pump.
10. Install the reservoir cap. 11. Check fir fluid leaks at all of the connections. If the power steering
fluid shows signs of air, repeat this procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Mercon V(R) Fluid Usage
TSB 07-1-7
01/22/07
MERCON(R) ATF REPLACED BY MERCON(R) V AS A SERVICE FLUID FOR SOME POWER
STEERING SYSTEMS
FORD: 1996-1997 Thunderbird 1996-2007 Crown Victoria, Mustang, Taurus 1998-2003 Escort
2000-2007 Focus 2002-2005 Thunderbird 2005-2006 Ford GT 2005-2007 Five Hundred, Freestyle
2006-2007 Fusion 1996-1997 Aerostar 1996-2007 E-Series, Explorer, Ranger 1997-2004 F-53
Motorhome Chassis 1997-2007 Expedition, F-150, F-Super Duty 1998-2003 Windstar 2000-2005
Excursion 2001-2003 Explorer Sport 2001-2005 Explorer Sport Trac 2001-2007 Escape 2004-2007
Freestar 2005-2007 Escape Hybrid 1996-1997 Cargo 1996-1998 L-Series 1996-1999 F- B-Series
2000-2007 F-650, F-750 2006-2007 Low Cab Forward
LINCOLN: 1996-1998 Mark VIII 1996-1999 Continental 1996-2007 Town Car 2000-2006 Lincoln
LS 2006 Zephyr 2007 MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator
2006-2007 Mark LT 2007 MKX
MERCURY: 1996-1997 Cougar 1996-2005 Sable 1996-2007 Grand Marquis 1999-2002 Cougar
2003-2004 Marauder 2005-2007 Montego 2006-2007 Milan 1997-2007 Mountaineer 1998-2002
Villager 2004-2007 Monterey 2005-2007 Mariner Hybrid, Mariner
ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a
service fluid for power steering systems originally requiring MERCON(R).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Mercon V(R) Fluid Usage > Page 8330
ACTION Beginning immediately all power steering applications requiring MERCON(R) can now be
serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids
labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission
Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining
inventory has been depleted.
SERVICE PROCEDURE
Service power steering Systems requiring MERCON(R) with MERCON(R) V or MERCON(R)
Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V.
CAUTION
APPLICATIONS RECOMMENDING TYPE F AUTOMATIC TRANSMISSION AND POWER
STEERING FLUID MUST CONTINUE TO USE THAT PARTICULAR FLUID. USE OF ANY
OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE
Parts Block
WARRANTY STATUS: Information Only
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Page 8331
Power Steering Fluid: Specifications /
/
Power Steering Fluid Type MERCON(R) ATF
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Specifications
Power Steering Fluid Cooler: Specifications
Fluid Cooler Nuts 59 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler >
Component Information > Specifications > Page 8335
Power Steering Fluid Cooler: Service and Repair
Removal
1. Disconnect the power steering return line hose at the power steering fluid cooler.
^ Allow the system to drain.
2. Remove the power steering fluid cooler to crossmember nuts.
3. Disconnect the power steering return hose. Remove the power steering fluid cooler.
Installation
1. Follow the removal procedure in reverse order. 2. Fill, and leak check the system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications
Power Steering Line/Hose: Specifications
Pressure Hose to Power Steering Pump 48 ft.lb
Power Steering Pump Bolts 18 ft.lb
Steering Gear Pressure Fittings 22 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Specifications > Page 8339
Power Steering Line/Hose: Service and Repair
Special Tools
Special Service Tool(s)
Removal
1. Refer to the Description and Operation for the hose routing and retention points.
Installation
1. When connecting a fitting with a seal ring, a new seal ring must be installed.
^ The special tool is used to install the return line connector seal and the pressure line connector
seal.
2. Fill and leak check the system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Mechanical Specifications
Power Steering Pump: Mechanical Specifications
Pump Pulley Bolts 18 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Mechanical Specifications > Page 8344
Power Steering Pump: Pressure, Vacuum and Temperature Specifications
Flow Rate 2.1 - 2.5 gal/min
Flow Rate @ 74 - 80 degrees C (165 - 175 degrees F) and
Engine Speed Set at 1500 RPM
Maximum Pressure 150 psi
Maximum Pressure @ 74 - 80 deg C (165 - 175 deg F) and
Engine Speed Set at 1500 RPM
Minimum Flow Rate 0.95 gal/min
Minimum Flow Rate @ 74 - 80 deg C (165 - 175 deg F), Power
Steering Analyzer Set at 5,102 kPa (750 psi) and Engine
Speed Set at Idle
Relief Pressure 1300 - 1480 psi
Flow Rate 2.2 - 2.6 gal/min
Flow Rate @ 74 - 80 degrees C (165 - 175 degrees F) and
Engine Speed Set at 1500 RPM
Maximum Pressure 150 psi
Maximum Pressure @ 74 - 80 deg C (165 - 175 deg F) and
Engine Speed Set at 1500 RPM
Minimum Flow Rate 1.15 gal/min
Minimum Flow Rate @ 74 - 80 deg C (165 - 175 deg F), Power
Steering Analyzer Set at 5,102 kPa (750 psi) and Engine
Speed Set at Idle
Relief Pressure 1300 - 1480 psi
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 8345
Power Steering Pump
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump
Power Steering Pump: Service and Repair Power Steering Pump
Special Tools
Special Service Tool(s)
Removal
1. Remove the engine cooling fan.
2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt.
4. Remove the power steering pump pulley.
1 Remove the bolts.
2 Remove the power steering pump pulley.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 8348
5. Disconnect the power steering return line hose at the power steering fluid reservoir.
^ Allow the system to drain.
6. Disconnect the power steering pressure hose from the power steering pump.
7. Disconnect the power steering fluid reservoir outlet hose from the power steering pump.
1 Compress and move the power steering fluid reservoir outlet hose clamp.
2 Disconnect the power steering fluid reservoir outlet hose from the power steering pump.
8. Remove the power steering pump.
1 Remove the bolts.
2 Remove the power steering pump.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 8349
1. Install the power steering pump.
1 Position the power steering pump.
2 Install the bolts.
2. Connect the power steering fluid reservoir outlet hose to the power steering pump.
1 Connect the power steering fluid reservoir outlet hose to the power steering pump.
2 Compress and move the power steering fluid reservoir outlet hose clamp into place.
3. Using the special tool, install a new seal on the power steering pressure hose.
4. Connect the power steering pressure hose to the power steering pump.
5. Connect the power steering return line hose to the power steering fluid reservoir.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 8350
6. Install the power steering pump pulley.
1 Position the power steering pump pulley.
2 Install the bolts.
7. Install the drive belt.
8. Tighten the power steering pump pulley bolts. 9. Install the engine cooling fan.
10. Fill, and leak check the system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump > Page 8351
Power Steering Pump: Service and Repair Power Steering Pump Pulley
Removal
1. Remove the engine cooling fan.
2. Loosen the power steering pump pulley bolts. 3. Remove the drive belt.
4. Remove the power steering pump pulley.
1 Remove the bolts.
2 Remove the power steering pump pulley.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 8357
7. Remove the two steering wheel back cover plugs.
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 8358
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 8359
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 8360
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 8361
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming and Arming > Page 8362
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Prove out the system means to turn the ignition switch from the OFF to the RUN position and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately six seconds and then turn off. If an air bag Supplemental
Restraint System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component
Information > Service and Repair
Key Reminder Switch: Service and Repair
For further information regarding the service of this component and the system that it is part of,
please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning
Devices.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Ignition Switch Lock Cylinder
Steering Column Lock: Service and Repair Ignition Switch Lock Cylinder
Functional Lock Cylinder
Removal
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Press the ignition switch lock cylinder release pin while pulling out the ignition switch lock
cylinder.
Installation
1. Follow the removal procedure in reverse order.
^ Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Non-Functional Lock Cylinder
Removal
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8370
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the steering wheel.
3. Twist off the cap from the ignition switch lock cylinder.
4. Remove the ignition switch lock cylinder.
^ Use a 1/8-inch diameter drill bit to drill out the lock cylinder retaining pin.
^ Use a 3/8-inch diameter drill to drill down the middle of the ignition lock key slot until the ignition
switch lock cylinder breaks loose.
^ Remove and discard the ignition switch lock cylinder and drill shavings from the steering column.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8371
5. Remove the bearing retainer.
6. Remove the bearing and the gear.
^ Thoroughly clean all drill shavings from the steering column and inspect it for damage.
Installation
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8372
1. Note: Use a new ignition switch lock cylinder.
Follow the removal procedure in reverse order. ^
Verify ignition switch lock cylinder operation.
2. Prove out the air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8373
Steering Column Lock: Service and Repair Key Release Button
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, remove the tilt wheel handle and shank.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component
Information > Service and Repair > Ignition Switch Lock Cylinder > Page 8374
2 Remove the upper and lower steering column shrouds.
5. Remove the key release lever.
1 Remove the key release lever bolt.
2 Remove the release lever handle and the spring.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
Steering Gear: Specifications
Type Rack and Pinion
Steering Gear Turns (Stop to Stop) 3.2/4.0
To Crossmember Stud Bolts and Nuts 111 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8378
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8379
Steering Gear: Testing and Inspection
1. Start and run the vehicle to operating temperature. 2. Set engine idle speed to 1200 rpm. 3.
Rotate the steering wheel to the RH stop, then turn the steering wheel 90° back from that position.
Turn the steering wheel slowly in a 15° to 30°
arc.
CAUTION: Do not hold the steering wheel against the stops for more than three to five seconds at
a time. Damage to the power steering pump will occur.
4. Turn the steering wheel another 90° Turn the steering wheel slowly in a 15° to 30° arc. 5. Repeat
the test with power steering fluid at different temperatures. 6. If a light grunt is heard or a low (50 200 Hz) shudder is present, this is a normal steering system condition. 7. If a loud grunt is heard, or
a strong shudder is felt, fill and purge the power steering system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8380
Steering Gear: Service and Repair
Removal
1. Place front wheels in the straight ahead position. Do not lock the steering column.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise the vehicle.
3. Remove the front wheel and tire assemblies.
4. Remove the radiator air deflector.
1 Remove the bolts.
2 Remove the radiator air deflector.
5. Loosen the LH tie-rod end jam nut.
6. Disconnect the tie-rod ends.
1 Remove and discard the cotter pins.
2 Remove the castellated nuts.
3 Disconnect the tie-rod ends from the steering knuckles. a Do not damage the tie-rod end boots.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8381
7. Remove the LH tie-rod end.
^ Count and record the number of turns required to remove the tie-rod end.
8. Remove the front stabilizer bar.
^ Mark the driver side end of the stabilizer bar for correct installation.
9. Remove the power steering cooler to crossmember nuts.
10. Remove the power steering fluid cooler.
1 Separate the power steering fluid return hose from the power steering fluid cooler. ^
Allow the system to drain.
2 Disconnect the power steering return line hose.
3 Remove the power steering fluid cooler.
11. Disconnect the lines at the gear.
1 Disconnect the power steering pressure hose.
2 Disconnect the power steering return hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8382
12. Plug ends of fluid lines and ports in steering gear to prevent damage and entry of dirt.
13. Rotate the steering column shaft to access the intermediate shaft pinch bolt. Remove the pinch
bolt. 14. Lower the vehicle. 15. Turn the steering wheel back to the straight ahead position. Turn
the ignition key to the locked position. 16. Raise the vehicle.
17. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is
disconnected or damage to the air bag sliding contact will
result.
Disconnect the intermediate shaft from the steering gear input shaft.
18. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the
steering gear fluid transfer tubes.
Remove the nuts.
19. Remove the stud bolts and washers.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8383
20. Remove the steering gear to crossmember insulator bushings.
21. Rotate the steering gear control valve housing toward the front of the vehicle. 22. Turn the
steering gear input shaft to the right until the stop is reached.
23. Move the steering gear as far to the RH side of the vehicle as possible.
24. Move the LH front wheel spindle tie-rod forward to clear the frame crossmember.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8384
25. Remove the steering gear from the vehicle.
Installation
1. Using the special tool, install new seals on the power steering return hose and power steering
pressure hose.
2. Note: Make sure the steering gear input shaft is turned to the left until the stop is reached.
Note: Handle the steering gear with caution to avoid damage to the fluid transfer tubes and to avoid
dimples in the tie-rod boots.
Turn the steering gear input shaft to the right until the stop is reached. Note the number of turns.
3. Note: Make sure the steering gear control valve housing is turned toward the front of the vehicle.
Install the steering gear into the RH opening of the crossmember.
4. Move the steering gear as far to the RH side of the vehicle as possible.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8385
5. Move the LH front wheel spindle tie-rod into the opening in the crossmember and move the
steering gear into position. 6. To place the steering gear in the straight ahead position, turn the
steering gear input shaft to the left by half the number of turns recorded
previously.
7. Rotate the steering gear control valve housing toward the rear of the vehicle.
8. Install the steering gear to crossmember insulator bushings as shown.
^ The large end of the metal sleeve must be positioned downward.
^ Check that the mounting surfaces on the crossmember are clean and free of debris.
9. Install the steering gear to crossmember washers and stud bolts.
^ The dished side of the washers face down.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8386
10. CAUTION: Hold the tops of the steering gear to crossmember stud bolts to avoid damaging the
steering gear fluid transfer tubes.
Install the nuts.
11. CAUTION: Do not rotate the steering wheel when the lower steering column shaft is
disconnected or damage to the air bag sliding contact will
result.
Connect the intermediate shaft to the steering gear input shaft. Install the pinch bolt.
12. Install the steering gear fluid lines.
1 Install the power steering return hose and then tighten tube nut.
2 Install the power steering pressure hose and tighten the tube nut.
13. Install the power steering fluid cooler.
1 Connect the power steering return line hose.
2 Connect the power steering return hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8387
3 Position the power steering fluid cooler and install the nuts.
14. Install the front stabilizer bar.
^ Orientate the front stabilizer bar as noted during removal.
15. Install the LH tie-rod end on the front wheel spindle tie-rod.
^ Rotate the tie-rod end the number of turns recorded during removal.
16. Connect the tie-rod ends to the steering knuckles.
1 Position the tie-rod ends on the steering knuckles.
2 Install the castellated nuts.
3 Install the new cotter pins. ^
Check that the brake dust shields are not bent and are not in contact with the outer tie-rod boot
seals.
17. Tighten the tie-rod jam nuts.
18. Install the radiator air deflector.
1 Position the radiator air deflector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Specifications
> Page 8388
2 Install the bolts.
19. Install the front wheel and tire assemblies.
20. Note: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Lower the vehicle.
21. Fill and leak check the power steering system. 22. Check the wheel alignment.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Specifications
Steering Shaft: Specifications
Lower Intermediate Shaft Pinch Bolt 36 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering
Wheel Is Loose
Steering Wheel: Customer Interest Interior - Leather Wrapping On Steering Wheel Is Loose
TSB 07-4-3
03/05/07
LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE
FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007
Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty
2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport
2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape
Hybrid 2007 Edge 2004-2007 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007
MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX
MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan
2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid
This article supersedes TSB 04-24-3 to update the vehicle model years.
ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather
coming loose from the spoke area.
ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke.
Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT
STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY
WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL.
CAUTION
AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Customer Interest for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On Steering
Wheel Is Loose > Page 8400
1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING
WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B.
2. Fold loose leather out of the way.
3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke.
4. Fold the leather back into its original position.
5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to
the wheel spoke (apply pressure for at least 30 seconds).
NOTE
THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE
REPAIR AREA.
6. Reinstall steering wheel.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT070403 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time.
DEALER CODING
CONDITION
BASIC PART NO. CODE
3600 33
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On
Steering Wheel Is Loose
Steering Wheel: All Technical Service Bulletins Interior - Leather Wrapping On Steering Wheel Is
Loose
TSB 07-4-3
03/05/07
LEATHER - WRAPPED STEERING WHEEL - LEATHER COMING LOOSE
FORD: 2000-2005 Thunderbird 2000-2007 Crown Victoria, Focus, Mustang, Taurus 2005-2007
Five Hundred, Freestyle 2006-2007 Fusion 1999-2003 Windstar 1999-2008 F-Super Duty
2000-2005 Excursion 2000-2007 E-Series, Expedition, Explorer, Ranger 2001-2003 Explorer Sport
2001-2007 Explorer Sport Trac 2001-2008 Escape 2004-2007 F-150, Freestar 2005-2008 Escape
Hybrid 2007 Edge 2004-2007 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 Lincoln LS 2000-2007 Town Car 2006 Zephyr 2007
MKZ 2000-2007 Navigator 2003-2005 Aviator 2006-2007 Mark LT 2007 MKX
MERCURY: 2000-2005 Sable 2000-2007 Grand Marquis 2005-2007 Montego 2006-2007 Milan
2000-2007 Mountaineer 2004-2007 Monterey 2005-2008 Mariner 2006-2008 Mariner Hybrid
This article supersedes TSB 04-24-3 to update the vehicle model years.
ISSUE Some vehicles equipped with leather-wrapped steering wheels may exhibit the leather
coming loose from the spoke area.
ACTION Apply Motorcraft Instant Gel Adhesive to re-adhere the loose leather to the wheel spoke.
Refer to the following Service Procedure.
SERVICE PROCEDURE
NOTE
IF RE-ADHERING LEATHER TO THE FRONT SIDE OF THE STEERING WHEEL ONLY, OMIT
STEPS 1 AND 6. STEERING WHEEL/AIR BAG ASSEMBLY REMOVAL IS NECESSARY ONLY
WHEN REPAIRING LOOSE LEATHER ON THE BACKSIDE OF THE STEERING WHEEL.
CAUTION
AVOID SKIN CONTACT WITH MOTORCRAFT INSTANT GEL ADHESIVE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Wheel: > 07-4-3 > Mar > 07 > Interior - Leather Wrapping On
Steering Wheel Is Loose > Page 8406
1. Remove the steering wheel (ONLY NECESSARY TO REPAIR BACKSIDE OF STEERING
WHEEL). Refer to Workshop Manual Sections 211-04 and 501-20B.
2. Fold loose leather out of the way.
3. Apply Motorcraft Instant Gel Adhesive evenly over the wheel spoke.
4. Fold the leather back into its original position.
5. Smooth the leather tuck in for neat appearance, and apply pressure until the leather is bonded to
the wheel spoke (apply pressure for at least 30 seconds).
NOTE
THE ADHESIVE SHOULD BE COMPLETELY SET AFTER 5 MINUTES. DO NOT PULL ON THE
REPAIR AREA.
6. Reinstall steering wheel.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
MT070403 Use SLIS Operations If Actual
Available; Claim Additional Time
Diagnosis Or Labor Performed As Actual Time.
DEALER CODING
CONDITION
BASIC PART NO. CODE
3600 33
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 8407
Steering Wheel: Specifications
Steering Wheel Bolt 25 - 34 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 8408
Steering Wheel: Service and Repair
Special Tool(s)
Special Service Tool(s)
Removal
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
Note: Make sure the wheels are in the straight-ahead position.
1. Disconnect the battery cable and wait at least one minute.
^ Disconnect the battery ground cable.
^ Disconnect the battery to starter relay cable.
2. Remove the driver air bag module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 8409
3. Remove the steering wheel bolt.
4. CAUTION: Removing the steering wheel without using a puller can damage the column
bearings.
Use the 2-Jaw Puller to remove the steering wheel.
5. Remove and discard the original steering wheel bolt. 6. Remove the steering wheel while routing
the wires from the air bag sliding contact through the steering wheel.
Installation
WARNING: Always wear safety glasses when repairing an air bag Supplemental Restraint System
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Technical
Service Bulletins > Page 8410
WARNING: Vehicle sensor orientation is critical for proper system operation. If a vehicle equipped
with an air bag Supplemental Restraint System (SRS) is involved in a collision, inspect the sensor
mounting bracket and wiring pigtail for deformation. Replace and properly position the sensor or
any other damaged Supplemental Restraint System (SRS) components whether or not the air bag
is deployed.
WARNING: To avoid accidental deployment and possible personal injury, the backup power supply
must be depleted before repairing or replacing any front or side air bag Supplemental Restraint
System (SRS) components and before servicing, replacing, adjusting or striking components near
the front or side air bag sensors, such as doors, instrument panel, console, door latches, strikers,
seats and hood latches. The side air bag sensors are located at or near the base of the B-pillar. To
deplete the backup power supply energy, disconnect the battery ground cable and wait at least one
minute. Be sure to disconnect auxiliary batteries and power supplies (if equipped).
1. Follow the removal procedure in reverse order. 2. Connect the battery cables. 3. Prove out the
air bag system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Specifications
Tie Rod End: Specifications
Tie Rod End Nut 44 - 59 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid
Ball Joint: Specifications Front Suspension Balljoint Inspection Job Aid
Front Lower Ball Joint
Measurement
..................................................................................................................................................
Between lower control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.032 in (0-0.8mm)
Reference Diagram .............................................................................................................................
............................................................................. A
Front Upper Ball Joint
Measurement
..................................................................................................................................................
Between upper control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.008 in (0-0.2mm)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 8420
Reference Diagram .............................................................................................................................
............................................................................. C
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 8421
Ball Joint: Specifications
Ball Joint Radial Play Lower Ball Joint Maximum 1/32 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications >
Front Suspension Balljoint Inspection Job Aid > Page 8422
Ball Joint: Specifications
Ball Joint Radial Play Upper Ball Joint Maximum 1/32 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Front Suspension Balljoint Inspection Job Aid
Ball Joint: Testing and Inspection Front Suspension Balljoint Inspection Job Aid
Front Lower Ball Joint
Measurement
..................................................................................................................................................
Between lower control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.032 in (0-0.8mm)
Reference Diagram .............................................................................................................................
............................................................................. A
Front Upper Ball Joint
Measurement
..................................................................................................................................................
Between upper control arm and knuckle
Deflection .............................................................................................................................................
........................................... 0-0.008 in (0-0.2mm)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8425
Reference Diagram .............................................................................................................................
............................................................................. C
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8426
Ball Joint: Testing and Inspection Ball Joint, Lower
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings.
3. Position a safety stand beneath the front suspension lower arm to be tested.
4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement
between the lower spindle arm and the front suspension
lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged
lower ball joint. Install a new ball joint as necessary.
5. While an assistant pulls and pushes the top of the tire, observe the relative movement between
the upper spindle arm and the front suspension
upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper
ball joint or loose pinch bolt joint. Tighten pinch bolt and nut as necessary. Install a new upper ball
joint as necessary.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Front Suspension Balljoint Inspection Job Aid > Page 8427
Ball Joint: Testing and Inspection Ball Joint, Upper
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise and support the vehicle.
2. Prior to performing any inspection of the ball joints, inspect the front wheel bearings.
3. Position a safety stand beneath the front suspension lower arm to be tested.
4. While an assistant pulls and pushes the bottom of the tire, observe the relative movement
between the lower spindle arm and the front suspension
lower arm ball joint. Any movement at or exceeding the specification indicates a worn or damaged
lower ball joint. Install a new ball joint as necessary.
5. While an assistant pulls and pushes the top of the tire, observe the relative movement between
the upper spindle arm and the front suspension
upper ball joint. Movement at or exceeding the specification indicates a worn or damaged upper
ball joint or loose pinch bolt joint. Tighten pinch bolt and nut as necessary. Install a new upper ball
joint as necessary.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 8428
Ball Joint: Service and Repair
Special Tool(s)
Special Tool(s)
Material
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the wheel and tire assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 8429
3. CAUTION: Do not reuse the torque prevailing design hub nut and washer assembly.
Remove and discard the hub nut and washer assembly.
4. CAUTION: Do not allow the disc brake caliper to hang suspended from the brake hose. Provide
a suitable support.
Remove the caliper support bracket bolts, then position the caliper and support bracket aside.
5. Remove the brake disc.
6. CAUTION: Do not use a hammer to separate the outboard front wheel halfshaft joint from the
wheel hub. Damage to the outboard CV
joint stub shaft threads and internal CV joint components may result.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 8430
Using the special tool, separate the outboard front wheel halfshaft joint from the wheel hub.
Remove the special tool.
7. Disconnect the front anti-lock brake sensor (ABS) wire from the vehicle frame.
1. Disconnect the ABS electrical connector.
2. Unclip the front ABS wire from the vehicle frame.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 8431
8. Using a suitable jack, support the front suspension lower arm.
9. CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can
cause damage to the front axle shaft.
Support the front axle shaft with wire.
10. Remove the tie-rod end castellated nut.
1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut.
11. CAUTION: Do not use a hammer to separate the tie-rod from the wheel knuckle or damage to
the wheel knuckle will result.
CAUTION: Do not damage the tie-rod boot when installing the special tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 8432
Using the special tool, separate the tie-rod end from the front wheel knuckle.
12. Remove the lower ball joint castellated nut.
1. Remove and discard the cotter pin. 2. Remove and discard the castellated nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 8433
13. Using the special tool, separate the front wheel knuckle from the front suspension lower arm
then, loosely install the lower ball joint castellated
nut.
14. Remove the pinch bolt and nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 8434
15. Remove the hand-tightened lower ball joint castellated nut, then remove the front wheel
knuckle.
16. Remove the snap ring from the ball joint. Discard the snap ring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and
Inspection > Page 8435
17. Using a suitable ball joint remover tool, remove the ball joint.
18. CAUTION: Do not damage the ball joint boot when installing the special tool.
NOTE: Clean and inspect the control arm ball joint bore for damage before installing a new ball
joint.
NOTE: Make sure the new ball joint snap ring is fully seated.
To install, reverse the removal procedure.
Always install new castellated nuts and cotter pins.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Solid Rear Axle
Control Arm Bushing: Service and Repair Solid Rear Axle
Removal and Installation
NOTE: The control arm bushings are not serviced separately. If the bushings require service, the
front suspension lower arm or the front suspension upper arm will have to be installed new.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Solid Rear Axle > Page 8441
Control Arm Bushing: Service and Repair Independent Rear Suspension
Lower Arm-Bushing
Lower Arm-Bushing Removal and Installation
NOTE: The lower arm bushings are not serviced separately. If the bushings require service, a new
lower arm must be installed.
Upper Arm Bushing
Upper Arm Bushing
Removal and Installation
1. Raise and support the vehicle.
2. Remove and discard the nut.
3. Remove the bolts and the flag nuts.
^ Discard the flag nuts.
4. Rotate the bushing upwards and remove the bushing.
5. CAUTION: Make sure the upper arm-to-frame mounting bolts are routed through the frame and
the arm before tightening.
NOTE: Do not tighten the bushing-to-arm nut until the vehicle is at curb ride height.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Solid Rear Axle > Page 8442
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Rear Cross-Member > System
Information > Service and Repair
Rear Cross-Member: Service and Repair
CROSSMEMBER - TRANSMISSION SUPPORT
Materials
Materials
Removal and Installation
1. Raise and support the vehicle.
2. Loosen, but do not remove, the nuts retaining the transmission insulator to the crossmember. 3.
Support the transmission.
4. Remove the six bolts retaining the crossmember to the frame.
5. Remove the nuts and the crossmember.
6. NOTE: Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or
equivalent to the transmission crossmember
mounting bolts.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair
Front Steering Knuckle: Service and Repair
Special Service Tool(s)
Removal
1. Remove the wheel hub.
2. Remove the torsion bar cover plate.
1 Remove the retaining bolts.
2 Remove the torsion bar cover plate.
3. Note: Before relieving the torsion bar tensions, measure and record the measurement of the
torsion bar adjustment bolt. This measurement will be
used as the preset depth for the new torsion bar adjustment bolt during installation.
Measure and record the length where indicated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 8450
4. Relieve the torsion bar tension.
1 Position the torsion bar tool and the adapters.
2 Tighten the torsion bar tool until the torsion bar adjuster lifts off of the adjustment bolt.
5. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive and must be replaced if it
is backed off or removed. Failure to do so can
cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment.
Remove the torsion, bar adjustment bolt and nut.
6. Loosen the torsion bar adjustment tool until the tension is off the torsion bar.
7. Reposition the anti-lock sensor wire.
1 Remove the front brake anti-lock sensor wire bracket bolt.
2 Reposition the anti-lock sensor wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 8451
8. CAUTION: Secure the front axle shaft to prevent it from overextending. Failure to do so can
cause damage to the front axle shaft.
Suspend the front axle shaft with wire.
9. Remove the tie rod end castellated nut.
1 Remove the tie rod end cotter pin.
2 Remove the tie rod end castellated nut.
10. Use the Pitman Arm Puller to separate the tie rod end.
^ Separate the tie rod end from the front wheel knuckle.
11. Remove the lower ball joint castellated nut.
1 Remove the lower ball joint cotter pin.
2 Remove the lower ball joint castellated nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 8452
12. Use the Pitman Arm Puller to separate the front wheel knuckle front the front suspension lower
arm.
13. Remove the pinch bolt. 14. Remove the front wheel knuckle.
Installation
1. Install the front wheel knuckle pinch bolt and nut.
1 Position the front wheel knuckle on the front suspension upper arm.
2 Install the pinch bolt and nut.
2. Install the front suspension arm lower ball joint castellated nut.
1 Position the front wheel knuckle,
2 Install the castellated nut.
3 Install a new cotter pin.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 8453
3. Install the tie rod end castellated nut.
1 Position the tie rod end.
2 Install the tie rod end castellated nut.
3 Install a new cotter pin.
4. CAUTION: The torsion bar adjustment bolt is coated with dry adhesive and must be replaced if it
is backed off or removed. Failure to do so can
cause the adjustment bolt to loosen up during operation and a loss of vehicle alignment.
Preload the torsion bar. 1
Tighten the torsion bar tool until the new adjustment bolt and nut can be installed.
2 Turn the adjustment bolt until preliminary adjustment marks are aligned.
5. Remove the torsion bar tool and adapters.
6. Install the torsion bar cover plate.
1 Position the torsion bar cover plate.
2 Install the retaining bolts.
7. Install the wheel hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Page 8454
8. Install the anti-lock sensor wire bracket bolt.
1 Position the anti-lock sensor wire.
2 Install the bolt.
9. Adjust the ride height.
10. Check the alignment.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair
Rear Knuckle: Service and Repair
Wheel Knuckle, Independent Rear Suspension
Special Tool(s)
1. CAUTION: Do not loosen the axle wheel hub retainer until the wheel and tire are removed from
the vehicle. Wheel bearing damage will occur if
the wheel bearing is unloaded with the weight of the vehicle applied.
Remove the wheel and tire assembly.
2. NOTE: Have an assistant press the brake pedal to keep the axle from turning.
Remove the nut and washer. ^
Discard the nut.
3. Remove the brake shield.
4. CAUTION: Do not damage the boot while separating the toe link from the knuckle.
Remove the nut and bolt and separate the toe link from the wheel knuckle. ^
Discard the nut.
5. CAUTION: Do not damage the boot while separating the ball joint from the knuckle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and
Repair > Page 8458
Remove the nut and bolt and separate the upper ball joint from the wheel knuckle. ^
Discard the nut.
6. CAUTION: Do not use a hammer to separate the outboard CV joint from the hub. Damage to the
threads and internal CV joint components may
result.
Using the special tool, press the outboard CV joint until it is loose from the hub.
7. Remove the nut and bolt and the wheel knuckle, hub and bearing as an assembly.
^ Discard the nut.
8. If necessary, remove the hub and bearing. 9. To install. reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle Alignment Link > Component
Information > Service and Repair
Rear Knuckle Alignment Link: Service and Repair
Toe Link, Independent Rear Suspension
1. Remove the wheel and tire assembly.
2. Remove the nut and bolt and separate the toe link from the wheel knuckle.
3. Remove the nut and the toe link. 4. To install, reverse the removal procedure. 5. Check and, if
necessary, adjust the rear toe.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8466
Compressor/Pump Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications
Suspension Control Module: Specifications
Air Suspension Control Module Mounting Screws 18 - 27 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 8470
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 8471
Suspension Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 8472
Suspension Control Module: Service and Repair
Removal
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Note: Ride heights must be reset for the air suspension module whenever the air suspension
module is replaced.
Disconnect the battery negative ground cable.
2. Remove the center instrument panel finish panel.
1 Remove the center instrument panel finish panel screws.
2 Disconnect the electrical connectors and remove the center panel finish panel.
3. Remove the air suspension control module.
1 Remove the air suspension control module screws.
2 Slide the air suspension control module down and out of the support bracket.
4. Disconnect the air suspension control module electrical connectors and remove the air
suspension control module.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension
Control Module > Component Information > Specifications > Page 8473
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
Note: When installing a new air suspension control module, ride height adjustment must be
performed. Ride Height Adjustments
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Locations > Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Ride Height
Sensor, Suspension Control > Component Information > Locations > Page 8479
Ride Height Sensor: Service and Repair
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the rear jack storage area. Failure to do so may result in unexpected
inflation or deflation of the air springs which may result in shifting of the vehicle during these
operations.
1. Raise and support the vehicle. 2. Remove the spare tire
3. Disconnect the height sensor electrical connector and remove the electrical connector harness
from the frame and apron to separate the push-in
fasteners
4. Release the upper and lower spring clip and pull the sensor from the ball studs.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension
Mode Switch > Component Information > Service and Repair
Suspension Mode Switch: Service and Repair
Removal
1. Remove the jack storage access cover.
2. Remove the retaining screw and air suspension switch bracket.
3. Remove the air suspension switch.
1 Disconnect the electrical connector.
2 Press the retaining clips and remove the air suspension switch from the bracket.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications
Spindle: Specifications
To Lower Ball Joint Nut 83 - 113 ft.lb
To Upper Ball Joint Nut 35 - 46 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Specifications
Stabilizer Link: Specifications
Front Stabilizer Bar Link Nuts 15 - 21 ft.lb
Rear Stabilizer Bar to Link Nut 50 - 68 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Dryer, Suspension Control > Component Information > Service and Repair
Air Dryer: Service and Repair
Removal
1. Remove the air compressor.
2. Remove the air compressor drier.
1 Remove the screw.
2 Rotate 90° to unlock then remove the air compressor drier.
Installation
1. Note: Inspect the O-ring for damage and replace as necessary. Lubricate the solenoid seal area
with Silicone Brake Caliper Grease and Dielectric
Compound D7AZ-19A331A or equivalent meeting Ford specification ESE-M1C171-A.
Note: When installing the air lines, make sure the white air line is fully inserted into the fitting for
correct installation.
Note: Ride height adjustments must be performed after the air compressor/drier is installed.
Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge
Air Line: Service and Repair Air Line Fluid Purge
Note: Perform this procedure if fluid (water or oil) is found in the rear air lines. Purge fluid from air
lines and replace affected components.
1. Disconnect air line at compressor air drier that is connected to front fill solenoid inlet. 2.
Disconnect air line at inlet of front fill solenoid. 3. Connect stop air line to disconnected air line and
blow out any water 4. Reconnect air line. 5. Disconnect air line at compressor air drier that is
connected to the rear fill solenoid inlet. 6. Disconnect air line at RR shock absorber. 7. Connect
scan tool to Data Link Connector (DLC). 8. Using the RIDE CONTROL OUTPUT command, turn on
the following actuators:
^ REAR_FIL (rear fill solenoid) ON.
9. Connect shop air line to disconnected air line and blow out any water.
10. Reconnect air line at RR shock absorber. 11. Disconnect air line at LR shock absorber. 12.
Using the RIDE CONTROL OUTPUT command, turn on the following actuators:
^ REAR_FIL(rearfill solenoid) ON.
^ GATE VALVE (front and rear gate solenoids) ON.
13. Connect shop air line to disconnected air line and blow out any water. 14. If oil was present in
air lines, replace BOTH LR and RR shock absorbers. (Do not replace s hock absorbers if only
water is in the lines.) 15. Replace compressor air drier. 16. Reconnect air line.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Air
Line, Suspension Control > Component Information > Service and Repair > Air Line Fluid Purge > Page 8498
Air Line: Service and Repair Air Line Repair
Note: A soapy water solution can be applied to the air lines to verify the location of air leaks.
1. If a leak is detected in an air line, it can be repaired by carefully making a good, clean, straight
cut. Trim back the outer covering of the air line 16
- 20 mm (0.63 - 0.78 inch) to reveal the white inner line. Install a repair fitting and wrap securely
with electrical tape.
2. If multiple leaks are detected, replace the entire air line.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Specifications
Compressor/Pump: Specifications
Air Compressor Assembly to Frame Mounting Bolts 13 - 17 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Specifications > Page 8502
Compressor/Pump: Service and Repair
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the rear jack storage area. Failure to do so may result in unexpected
inflation or deflation of the air springs which may result in shifting of the vehicle during these
operations.
1. Raise and support the vehicle. 2. Remove the spare tire.
3. Disconnect the air compressor electrical connector.
4. Disconnect the air line from the drier.
1 Compress the quick connect locking ring and pull out the air line.
2 Remove the air line from the drier.
5. Remove the air compressor assembly from the vehicle.
1 Remove the air compressor bolts.
2 Remove the air compressor assembly.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump, Suspension Control > Component Information > Specifications > Page 8503
1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for
correct installation.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Compressor/Pump Relay, Suspension Control > Component Information > Locations > Page 8507
Compressor/Pump Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill
Level Control Solenoid Valve: Service and Repair Solenoid Valve-Rear Fill
Special Service Tool(s)
Removal
1. Connect New Generation STAR (NGS) Tester to the Data Link Connector (DLC). 2. Select the
RIDE CONTROL OUTPUT screen and turn on the following solenoids to vent the entire system of
air and to lower the vehicle to its
lowest attainable height: ^
REAR FILL (rear fill solenoid).
^ GATE VALVE (gate solenoid[s]).
^ VENT (vent solenoid).
3. Raise and support the vehicle. 4. Remove the spare tire.
5. Remove the solenoid valve from the frame.
6. Compress the quick connect locking ring and pull out the air line.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 8512
7. Disconnect the solenoid valve electrical connector.
Installation
1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for
correct installation.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 8513
Level Control Solenoid Valve: Service and Repair Solenoid Valve-Rear Gate
Special Service Tool(s)
Removal
1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT
screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle
to its
lowest attainable height: ^
REAR FILL (rear fill solenoid).
^ GATE VALVE (gate solenoid[s]).
^ VENT (vent solenoid).
3. Raise and support the vehicle. 4. Remove the spare tire. 5. Remove the evaporative canister.
6. Remove the solenoid valve from the frame.
7. Compress the quick connect locking ring and pull out the air line.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Level
Control Solenoid Valve > Component Information > Service and Repair > Solenoid Valve-Rear Fill > Page 8514
8. Disconnect the solenoid valve electrical connector.
Installation
1. Note: When installing the air lines make sure the white air line is fully inserted into the fitting for
correct installation.
To install, reverse the removal Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Locations > Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride
Height Sensor, Suspension Control > Component Information > Locations > Page 8519
Ride Height Sensor: Service and Repair
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the rear jack storage area. Failure to do so may result in unexpected
inflation or deflation of the air springs which may result in shifting of the vehicle during these
operations.
1. Raise and support the vehicle. 2. Remove the spare tire
3. Disconnect the height sensor electrical connector and remove the electrical connector harness
from the frame and apron to separate the push-in
fasteners
4. Release the upper and lower spring clip and pull the sensor from the ball studs.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications
Suspension Control Module: Specifications
Air Suspension Control Module Mounting Screws 18 - 27 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 8523
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 8524
Suspension Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 8525
Suspension Control Module: Service and Repair
Removal
1. CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Note: Ride heights must be reset for the air suspension module whenever the air suspension
module is replaced.
Disconnect the battery negative ground cable.
2. Remove the center instrument panel finish panel.
1 Remove the center instrument panel finish panel screws.
2 Disconnect the electrical connectors and remove the center panel finish panel.
3. Remove the air suspension control module.
1 Remove the air suspension control module screws.
2 Slide the air suspension control module down and out of the support bracket.
4. Disconnect the air suspension control module electrical connectors and remove the air
suspension control module.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Control Module > Component Information > Specifications > Page 8526
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
Note: When installing a new air suspension control module, ride height adjustment must be
performed. Ride Height Adjustments
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) >
Suspension Mode Switch > Component Information > Service and Repair
Suspension Mode Switch: Service and Repair
Removal
1. Remove the jack storage access cover.
2. Remove the retaining screw and air suspension switch bracket.
3. Remove the air suspension switch.
1 Disconnect the electrical connector.
2 Press the retaining clips and remove the air suspension switch from the bracket.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Specifications
Suspension Spring ( Coil / Leaf ): Specifications
Rear Spring Shackle Lower Bolt and Nut 85 ft.lb
Rear Spring to Front Frame Bracket Bolt and Nut 66 ft.lb
Rear Spring U-bolt Nut 76 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear
Suspension Spring ( Coil / Leaf ): Service and Repair Rear
Shock Absorber and Spring Assembly
Removal and Installation
1. Remove the wheel and tire assembly.
2. Remove and discard the nuts.
3. Remove the nut and the stabilizer bar link.
^ Discard the nut.
4. Remove the nut and the bolt.
^ Discard the nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear > Page 8535
5. Remove the bolt, flag nut and the shock absorber and spring as an assembly.
^ Discard the flag nut.
6. Using a suitable spring compressor, compress the spring until the tension is released from the
shock absorber.
7. While holding the flats of the washer, remove the nut.
^ Remove the shock absorber.
^ Discard the nut.
8. Remove the washer, bushing and the upper mount.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear > Page 8536
9. Remove the insulator.
10. Remove the dust shield. 11. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear > Page 8537
Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring
Spring Tools
Special Service Tool(s)
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which
can result in shifting of the vehicle during these operations.
Turn the air suspension service switch off, if so equipped.
2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly.
4. Use the Hi-Lift Jack to support the rear axle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Rear > Page 8538
5. Separate the rear spring from the rear axle.
1 Remove the four nuts.
2 Remove the two U-bolts.
3 Position the rear spring plate aside.
6. Remove the rear spring.
1 Remove the bolt and nut.
2 Remove the bolt and nut.
3 Remove the roar spring.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications
Suspension Strut / Shock Absorber: Specifications
Front To Lower Arm Nuts 15 - 21 ft.lb
To Frame Mounting Nut 30 - 41 ft.lb
Rear Shock Absorber to Frame Nuts 17 ft.lb
Shock Absorber Lower Bolt 46 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Solid Rear Axle
Suspension Strut / Shock Absorber: Service and Repair Solid Rear Axle
Special Service Tool(s)
Removal
WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing of an air suspension vehicle. This can be accomplished by turning off the air
suspension switch located in the rear jack storage area. Failure to do so may result in unexpected
inflation or deflation of the air springs which may result in shifting of the vehicle during these
operations.
WARNING: The low pressure gas shock absorbers are charged with nitrogen gas 930 kPa (135
psi). Do not attempt to open, puncture, or apply heat to the shock absorbers.
1. Connect scan tool to the Data Link Connector (DLC). 2. Select the RIDE CONTROL OUTPUT
screen and turn on the following solenoids to vent the entire system of air and to lower the vehicle
to its
lowest attainable height: ^
REAR FILL (rear fill solenoid).
^ GATEVALVE(gate solenoid[s]).
^ VENT (vent solenoid).
3. Raise and support the vehicle. 4. Remove the spare tire.
5. Use Hi-Lift Transmission Jack to support the rear axle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Solid Rear Axle > Page 8544
6. Remove the rear shock absorber electrical connector from the rear crossmember and disconnect
the electrical connector.
7. Disconnect the air line from the shock absorber.
^ Compress the quick connect locking ring and pull out the air line.
8. Remove the shock absorber lower retaining nut and bolt and swing the shock absorber out of the
lower mounting bracket.
9. Remove the attaching nuts on top of the rear crossmember and remove the shock absorber.
Installation
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Solid Rear Axle > Page 8545
1. Note: When installing air lines make sure the white air line is fully inserted into the fitting for
correct installation.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Solid Rear Axle > Page 8546
Suspension Strut / Shock Absorber: Service and Repair Independent Rear Suspension
Shock Absorber and Spring Assembly
Removal and Installation
1. Remove the wheel and tire assembly.
2. Remove and discard the nuts.
3. Remove the nut and the stabilizer bar link.
^ Discard the nut.
4. Remove the nut and the bolt.
^ Discard the nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Solid Rear Axle > Page 8547
5. Remove the bolt, flag nut and the shock absorber and spring as an assembly.
^ Discard the flag nut.
6. Using a suitable spring compressor, compress the spring until the tension is released from the
shock absorber.
7. While holding the flats of the washer, remove the nut.
^ Remove the shock absorber.
^ Discard the nut.
8. Remove the washer, bushing and the upper mount.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Solid Rear Axle > Page 8548
9. Remove the insulator.
10. Remove the dust shield. 11. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component Information
> Specifications
Suspension Travel Bumper: Specifications
Front Jounce Bumper to Frame Nut 18 - 26 ft.lb
Rear Jounce Bumper Nut 15 - 21 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
Torsion Bar: Specifications
Cover Plate Bolts 35 - 46 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
> Page 8555
Torsion Bar: Service and Repair
Special Service Tool(s)
Removal
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs or
shocks, which can result in shifting of the vehicle during these operations.
Raise the vehicle on a hoist.
2. Remove the torsion bar cover plate.
1 Remove the torsion bar cover plate bolts.
2 Remove the torsion bar cover plate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
> Page 8556
3. Note: Before relieving the torsion bar tension, measure and record the measurement of the
torsion bar adjustment bolt. This measurement will be
used as the preset depth for the new torsion bar adjustment bolt during installation.
Make preliminary adjustment. ^
Measure and record the length where indicated.
4. Relieve the torsion bar tension.
1 Position the Torsion Bar Tool and adapters.
2 Tighten the Torsion Bar Tool until the torsion bar adjuster lifts off the adjustment bolt.
5. CAUTION: The torsion bar adjustment bolt is coated with: dry adhesive; and must be replaced if
it is backed offer removed. Failure to do so can
cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment.
Remove the torsion bar adjustment bolt and nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
> Page 8557
6. Loosen the Torsion Bar Tool until the tension is removed from the torsion bar.
7. Remove the torsion bar.
1 Mark the torsion bar and the adjuster for proper installation.
2 Remove the torsion bar insulator.
3 Grasp the torsion bar, and pull it free from the front suspension lower arm.
Installation
1. Position the torsion bar and the torsion bar adjuster.
2. Install the torsion bar adjuster.
1 Align the marks on the torsion bar and the torsion bar adjuster, then install the torsion bar
adjuster.
2 Position the torsion bar insulator.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Torsion Bar > Component Information > Specifications
> Page 8558
3. CAUTION: The torsion bar adjustment bolt is coated with: dry adhesive; and must be replaced if
it is backed off or removed. Failure to do so can
cause the adjustment bolt to loosen during operation and cause a loss of vehicle alignment.
Preload the torsion bar. 1
Install the Torsion Bar Tool and the adapters.
2 Tighten the Torsion Bar Tool until the new adjustment bolt and nut can be installed.
3 Turn the adjustment bolt until the preliminary adjustment measurement (recorded length of the
old adjustment bolt) is reached.
4. Install the torsion bar cover plate.
1 Position the torsion bar cover plate.
2 Install the torsion bar cover plate bolts.
5. Note: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Lower the vehicle.
6. Adjust the ride height. 7. Check the alignment.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications
Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
Lubricate the lip of the new wheel bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing
and Inspection > Wheel Bearing Check
Wheel Bearing: Testing and Inspection Wheel Bearing Check
1. Raise and support the vehicle.
^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can
be the cause of a strain problem.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH
CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
2. Spin the tire by hand to check the wheel bearings for roughness.
NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow
free movement of the tire and wheel assembly.
3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing
and Inspection > Wheel Bearing Check > Page 8564
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Testing
and Inspection > Wheel Bearing Check > Page 8565
Wheel Bearing: Testing and Inspection Wheel Bearing Inspection
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise the vehicle until the tire is off the floor.
2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of
the following actions.
^ On 4x2 vehicles, adjust the front wheel bearings.
^ On 4x4 vehicles, install a new wheel hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Solid Rear Axle
Wheel Bearing: Service and Repair Solid Rear Axle
Special Tools
Special Tools
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Solid Rear Axle > Page 8568
Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service
and Repair > Solid Rear Axle > Page 8569
Wheel Bearing: Service and Repair Independent Rear Suspension
Wheel Bearing
Removal And Installation
1. Remove the wheel knuckle.
2. CAUTION: Make sure that the press adapter outside diameter is slightly smaller than the hub
outside diameter or damage to the knuckle will
result.
Using a suitable press, remove the hub from the bearing.
- Discard the hub.
3. NOTE: The retainer ring is tapered and must be installed flat side down.
Remove the retainer ring.
- Discard the retainer ring.
4. Using a suitable press, remove the bearing from the wheel knuckle.
- Discard the bearing.
5. CAUTION: The hub and bearing cannot be reused after disassembly.
To install. reverse the removal Procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
Wheel Hub Nut 157-213 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation
Vehicle Lifting: Description and Operation
JACKING
WARNING: ^
THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR
TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE
ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE REAR
JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED INFLATION OR
DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF THE VEHICLE
DURING THESE OPERATIONS.
^ DO NOT RUN THE ENGINE WHEN JACKING THE VEHICLE. THE WHEELS CONTACTING
THE GROUND COULD CAUSE THE VEHICLE TO MOVE.
^ MAKE SURE THE JACK AND JACK STANDS ARE PROPERLY LOCATED TO PREVENT THE
VEHICLE FROM FALLING.
^ WHEEL CHOCKS SHOULD BE USED TO PREVENT THE VEHICLE FROM ROLLING AND
FALLING OFF THE JACK.
Jacking Points - Front The front jacking point is a tab that extends from the lower control arm.
Jacking Points - Rear
1. The rear jacking points are located on the rear axle tube.
CAUTION: ^
Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover and
adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
LIFTING
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Vehicle Lifting > Component Information >
Description and Operation > Page 8578
Lifting Points Locate front hoist adapters and rear hoist adapters (top of frame arc) as indicated.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE
REAR JACK STORAGE AREA. FAILURE TO DO SO MAY RESULT IN UNEXPECTED
INFLATION OR DEFLATION OF THE AIR SPRINGS WHICH MAY RESULT IN SHIFTING OF
THE VEHICLE DURING THESE OPERATIONS.
CAUTION: ^
Damage to the suspension, exhaust or steering linkage components may occur if care is not
exercised when positioning the hoist adapters prior to lifting the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8587
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8588
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8589
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8590
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8591
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8592
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8593
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8594
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8595
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement > Page 8596
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance
Tires: Recalls Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8605
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8606
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8607
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8608
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8609
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8610
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Recalls: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label > Page 8611
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
Tires: Customer Interest 4X4/AWD System - Shudder On Accel/Decel/Binding On Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 8617
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 8618
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Customer Interest: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns > Page 8619
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 8625
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 8626
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 8627
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 8632
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8637
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8638
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8639
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8640
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8641
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8642
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8643
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8644
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8645
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
> Page 8646
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement
Technical Service Bulletin # 00L12 Date: 010101
Information
00L12
SPECIAL FIELD ACTION
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Original - January 2001
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1, February 5, 2001 - Updated Information
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Supplement # 2, February 19, 2001 - Updated Information
All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8651
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8652
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8653
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8654
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8655
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8656
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8657
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8658
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8659
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8660
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8661
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8662
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8663
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8664
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8665
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8666
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8667
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8668
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8669
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8670
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8671
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8672
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8673
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page
8674
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000:
Certification Label Non-Compliance
Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8683
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8684
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8685
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8686
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8687
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8688
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation
Label > Page 8689
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns
Tires: All Technical Service Bulletins 4X4/AWD System - Shudder On Accel/Decel/Binding On
Turns
TSB 08-21-11
10/27/08
4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON
ACCELERATION/DECELERATION OR BINDING ON SLOW TURNS
FORD: 1997-2008 Expedition, Explorer 2006-2008 F-150 2007-2008 Explorer Sport Trac 2008
F-150
LINCOLN: 1998-2008 Navigator 2003-2005 Aviator
MERCURY: 2005 Mountaineer 2006-2008 Mountaineer
ISSUE Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and
equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow
speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur
with the vehicle being operated in the awd/auto 4x4 mode. The shudder/binding may be due to
incorrect tire circumference or improper tire inflation pressures.
ACTION Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
NOTE
THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008
EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS.
NOTE
VEHICLES ON THE LIST MAY REQUIRE REPLACEMENT OF TIRE/S IF THE TIRE
CIRCUMFERENCE AVERAGE BETWEEN THE FRONT AND REAR AXLES ARE OUTSIDE OF
THE 1/2 INCH SPECIFICATION OR IF THE TIRE CIRCUMFERENCE FROM SIDE TO SIDE ON
EITHER AXLE EXCEEDS 1/2 INCH DIFFERENCE, THE SMALLER TIRE(S) MUST BE
REPLACED.
NOTE
REVIEW THE WARRANTY AND POLICY MANUAL FOR FORD MOTOR COMPANY TIRE
REPLACEMENT WARRANTY BEFORE PERFORMING THE SERVICE PROCEDURE.
NOTE
ONLY USE REPLACEMENT TIRE AND WHEEL THAT ARE THE SAME SIZE, LOAD INDEX,
SPEED RATING AND TYPE (SUCH AS P-METRIC VERSUS LT-METRIC OR ALL-SEASON
VERSUS ALL-TERRAIN) AS THOSE ORIGINALLY PROVIDED BY FORD. THE
RECOMMENDED TIRE AND WHEEL SIZE MAY BE FOUND ON EITHER THE SAFETY
COMPLIANCE CERTIFICATION LABEL OR THE TIRE LABEL WHICH IS LOCATED ON THE
B-PILLAR OR EDGE OF THE DRIVER'S DOOR.
NOTE
ON SOME 4WD MODELS, THE INITIAL SHIFT FROM 2WD TO 4WD WHILE THE VEHICLE IS
MOVING CAN CAUSE A MOMENTARY CLUNK AND/OR BRIEF RATCHETING SOUND. THESE
SOUNDS ARE NORMAL AS THE FRONT DRIVETRAIN COMES UP TO SPEED AND IS NOT
CAUSE FOR CONCERN.
1. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the
driver's door.
2. If the tire size does not match the label, this procedure does not apply, follow normal Workshop
Manual (WSM) diagnostics.
3. If the tire size is correct, ensure tire pressures are within specifications.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 8695
4. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02.
5. Disconnect all wiring going to the transfer case and road test.
6. Is the shudder/binding present?
a. If the shudder/binding is still present, do not continue with this procedure, continue with WSM
normal diagnostic for 4X4.
b. If the shudder/binding is gone, proceed to Step 7.
7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected.
8. Using a tailor's tape or flexible measuring tape and measure the circumference of all four (4)
tires and record the measurements. (Figure 1)
9. Calculate the average of the circumference of the two (2) front tires and calculate the average of
the circumference of the two (2) rear tires. (Figure 2)
10. If the difference between these two averages is greater than 1/2" (12.7 mm), front to back or
side to side, replace the smallest circumference tire(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 8696
and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.
NOTE
WARRANTY COVERAGE ELIGIBILITY STARTS WITH 2007 NEW VEHICLE LIMITED
WARRANTY COVERAGE.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits
are determined by the identified causal part.
OPERATION DESCRIPTION TIME
082111A 2003-2008 Expedition, 1.1 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111A 1997-2002 Expedition, 1.0 Hr.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace One (1) Tire (Do Not Use With 1007A)
082111B 2003-2008 Expedition, 1.4 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace TWO Tires. (Do Not Use With 1007A)
082111B 1997-2002 Expedition, 1.2 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley Davidson, Mountaineer, 1997-2008 Explorer,
2007-2008 Explorer Sport Trac, And 2008 F-150 Limited 4X4: Perform Diagnosis Outlined In
Service Procedure And Replace Two (2) Tires (Do Not Use With 1007A)
082111C 2003-2008 Expedition, 1.7 Hrs.
Navigator, 2003-2005 Aviator, Explorer, Mountaineer 4X4: Perform Diagnosis Outlined In Service
Procedure And Replace Three (3) Tires (Do Not Use With 1007A)
082111C 1997-2002 Expedition, 1.4 Hrs.
1998-2002 Navigator, 2006-2008 F-150 Harley
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 08-21-11 > Oct > 08 > 4X4/AWD System - Shudder On
Accel/Decel/Binding On Turns > Page 8697
Davidson, Mountaineer, 1997-2008 Explorer, 2007-2008 Explorer Sport Trac, And 2008 F-150
Limited 4X4: Perform Diagnosis Outlined In Service Procedure And Replace Three (3) Tires (Do
Not Use With 1007A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7A195 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 8702
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement
Technical Service Bulletin # 00L12 Date: 010101
Information
00L12
SPECIAL FIELD ACTION
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Original - January 2001
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Attachment III ^
Technical Information
Customer Notification Letter
Supplement # 1, February 5, 2001 - Updated Information
All 2001 Model Year Passenger Cars and Light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Supplement # 2, February 19, 2001 - Updated Information
All 2001 Model Year Passenger Cars and light Trucks up to and Including F550 Super Duty
Vehicles Sold in the U.S., U.S. Territories, Mexico, and Canada - Warranty Guide Supplement
Special Field Action 00L12, Supplement # 1 dated 2/05/01 - Updated Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8707
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8708
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8709
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8710
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8711
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8712
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8713
Attachment III ^
Technical Information
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8714
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8715
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8716
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8717
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8718
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8719
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8720
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8721
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8722
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8723
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8724
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8725
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8726
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8727
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8728
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Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8729
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8730
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 8736
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement
Technical Service Bulletin # 01B77 Date: 011001
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8741
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Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8742
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8743
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8744
Attachment I - Administrative Information
OASIS
OASIS must be used to determine vehicle eligibility.
IMPORTANT:
When an eligible vehicle is at the dealership for service, OASIS must be contacted to determine if
Owner Notification Program 01B77 is open. If 01B77 is listed in OASIS as open, it is important that
the vehicle is inspected for eligible tires. If the eligible vehicle is not equipped with 15-, 16-, or
17-inch Firestone Wilderness AT tires a claim must be submitted using labor operation 01B77A to
close the program. If an affected vehicle does not have 01B77 open, this may indicate that a refund
or tire replacement has already been processed on this vehicle.
Some Ford and Lincoln Mercury vehicles not listed in the AFFECTED TIRES AND VEHICLES list
may have 15-, 16-, or 17-inch Firestone Wilderness AT tires installed. These vehicles are covered
under this program, but will not be active in OASIS. Contact the Special Service Support Center at
1-800-325-5621 to obtain prior approval before performing the repair or issuing a refund. This will
insure that a previous repair/refund has not been performed on the vehicle.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
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Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8745
^ Enter the full part number of the replacement tire with the quantity of tires replaced. Tires will be
reimbursed at AtW Dealer cost + 25% (wheel weights and valve stems incl.).
^ Use the appropriate labor operation(s) from Attachment II.
^ Freight is reimbursable at actual cost in the miscellaneous expense area of the claim.
NOTE:
Freight is only reimbursable for rural dealers whose only means of acquiring tires is by having them
shipped in via common carrier. Dealers are encouraged to arrange for shipment of 4 or more tires
at a time.
^ Dealers can no longer claim tire disposal for ONP 01B77. See the "National Tire Recovery and
Recycle Program". You may still claim any applicable local waste tax - enter OTHER in the
expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires on the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry.
RELATED DAMAGE
Vehicle damage caused by a tire related failure is not covered by this program. Refer to the
Warranty and Policy Manual for proper claiming procedure for vehicles covered by the Ford
Bumper-to-Bumper Tire Warranty (model years 2001 and 2002). All other pre-2001 model year
vehicles with alleged tire related vehicle damage should be handled through the Firestone claims
process, or by referring the customers to their insurance company.
Damage related to replacement of tires should be handled as described in the Warranty and Policy
Manual.
OWNER REFUND
With the increased availability of replacement tires, it will no longer be necessary for customers to
pay out-of-pocket expenses for tires. Therefore, refund requests for tires purchased after
November 15, 2001 will no longer be granted. Owners will be notified of the refund expiration date
and will be directed to a Ford or Mercury dealer They are directed to an authorized retailer only if
the Ford or Mercury dealer cannot meet their scheduling needs or tires are not in stock. All Ford
and Mercury dealers (AtW and non-AtW dealers) are required to process refunds for customers
who purchase tires prior to November 15, 2001.
The following rules apply to refunds for tires purchased from August 1, 2001 through November 15,
2001:
Refunds will be processed for vehicles listed under "AFFECTED TIRES AND VEHICLES", and for
other Ford and Lincoln Mercury vehicles that have 15-. 16-, or 17-inch Wilderness AT tires
installed.
^ The customer must provide the original paid receipt (a copy of their paid receipt is acceptable on
an exception basis in instances where the owner requires the original for another purpose (e.g.
extended tire warranty or purchase rebate). The dealer will attach the receipt to the dealer file copy
of the refund claim (see claim instructions below).
^ Dealers will be reimbursed to immediately disable tires returned for a refund (see claiming
instructions for refunds and Attachment II for labor operations).
^ The tires must be purchased August 1, 2000 through November 15, 2001 to be eligible for a
refund (through October 31, 2001 for 1995 and 1996 F-150 owners).
^ Customers requesting refunds for tire replacement May 22, 2001 through November 15, 2001
must provide either:
NOTE:
This does not apply to 1995 and 1996 F-150 customers.
^ The Firestone Wilderness AT tires that were replaced. Returned tire(s) are to be disabled by the
dealership. Ford will reimburse the dealer to disable (see claim instructions below and use labor
operation 01B77G). If tires are brought in for refund with the DOT codes missing dealers should not
process the refund.
^ A section of the old tire(s) containing the DOT codes from each of the Firestone Wilderness AT
tires that were replaced (To be cut from the Wilderness AT tires that were replaced by the outside
repair facility) (use labor operation 01B77L). Dealers should deface (cut in pieces or make code
unreadable) the DOT sections of the tire so they cannot be used to obtain another refund. If
sections are brought in for refund with the DOT code defaced dealers should not process the
refund.
NOTE:
The DOT Code Identification Guide has been developed to help dealers determine if the DOT
sections returned to the dealership are from 15-, 16-,
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Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8746
or 17-inch Firestone Wilderness AT tires. Use the DOT Code Identification Guide in conjunction
with the bulletin section "What if the Vehicle has a Mix of Affected and Non-Affected Tires" to
determine how many tires are eligible for refund.
NOTE:
Ford will allow customers to file for a refund (with or without tires) for tires purchased after May 22
through June 30, 2001 because customers may not have tires to turn in. Customers must provide a
paid receipt indicating tire replacement before July 1, 2001 in order to process a refund without
tires or DOT sections. Customers who purchase tires after June 30, 2001 must provide tires or
DOT sections.
Ford will reimburse customers the following amounts:
^ Tires purchased from August 1, 2000 through May 22, 2001, the actual cost as stated on their
paid receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes.
^ (1995 and 1996 F-150 vehicle only) Tires purchased from August 1, 2000 through October 31,
2001, the actual cost as stated on their paid receipt for replacing tires, mounting, balancing, valve
stems, disposal, and taxes. No DOT section required.
^ Tires purchased May 23, 2001 through November 15, 2001, the actual cost as stated on the
receipt for replacing tires, mounting, balancing, valve stems, disposal, and taxes up to a maximum
of $110 per tire for 15 inch, and $130 per tire for 16 and 17 inch tires.
^ Refunds will not be granted for tires purchased after November 15, 2001.
Note:
If an owner pays for the replacement of their tires after November 15, 2001, the dealer may handle
on a case by case basis following the procedure in Attachment II.
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8747
CLAIMS PREPARATION FOR REFUNDS (USE THIS PROCEDURE FOR ALL REFUND
REQUESTS)
NOTE:
Tires must be purchased prior to November 15, 2001
^ Enter claims using DWE.
^ Refer to ACESII User Manual for claims preparation and submission information.
^ Enter information on a Recall/ONP claim type. DO NOT use a Warranty Claim type.
^ Program code 01B77.
^ When a customer brings in their old tires and is seeking a refund, use labor operation 01B77G
(disable) and 01B77L (refund administration allowance) from Attachment II.
^ If a customer brings in the old DOT codes removed from the old tires - use labor operation
01B77L only.
^ The Miscellaneous Expense Code "ADMIN" will not be accepted under this program. A labor
operation 01B77L has been provided to cover administrative costs.
^ Enter REFUND in the miscellaneous area of the claim.
^ Dealers will no longer be able to claim tire disposal for ONP 01B77. See the "National Tire
Recovery and Recycle Program" You may still claim any applicable local waste tax - enter OTHER
in the expense area of the claim with the actual cost.
^ Enter each unique (complete 10 or 11 digit) DOT codes of the replaced tires in the diagnostic
code entry screen in the field marked "other". If the DOT codes cannot be completely entered in the
space provided in the diagnostic code area, use the technician comment area to complete the data
entry. If the tires were replaced prior to May 23, 2001 (or November 1, 2001 for 1995 and 1996
F150 customers) the DOT may not be available, in this case record the brand, make and size of
the tires in the technician comments area of the claim.
RENTAL CARS
TAP allowances have been increased specifically for this owner notification program. Refer to Don
Brunner letter.
DOT REGISTRATION OF NEW TIRES
Dealers are required to register the DOT number of every tire sold to meet federal tire registration
requirements. Ford has established a partnership with CIMS to assist dealers in registering these
DOT codes. Information is available on QCDealer.com under CIMS Tire Registration or by
contacting CIMS
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Page 8748
at 330-794-9190.
NON-FORD OR LINCOLN MERCURY VEHICLES WITH FIRESTONE WILDERNESS AT
Non-Ford or Lincoln Mercury vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires
installed by a Certified Tire Dealer (AtW or Ford Tire Program) are eligible for replacement. The
repair should be submitted using a Warranty/ESP claim type form. The dealer must enter Program
Code "P19", this will allow the repair to be submitted without a VIN. The causal part must be TIRE,
with the actual part numbers for reimbursement at dealer cost plus 25%, and use actual time for
labor reimbursement. These types of claims cannot be submitted as an Owner Notification Repair
type.
Attachment II - Parts and Labor Information
LABOR ALLOWANCES
NON-AtW DEALERS SERVICING IN-STOCK UNITS OR CUSTOMER VEHICLES
NOTE:
Non-Certified Tire Dealers (AtW or Ford Tire Program) who have vehicles in stock, or customer
vehicles with 15-, 16-, or 17-inch Firestone Wilderness AT tires must send the vehicle to a Certified
Tire Dealer (AtW or Ford Tire Program), or an approved tire retailer participating in the program to
have the tire replacement performed. The non-Certified Tire Dealer (AtW or Ford Tire Program) will
submit a 01B77 ONP claim using the miscellaneous expense code of "SCHP" (with a dollar value
of $15.00 to cover administrative costs). Do not claim the "Admin" labor operation.
PARTS REQUIREMENTS
Tire Ordering Information
^ Dealers are required to install only tires from the Approved Tire List for vehicles originally
equipped with 15-, 16-, and 17-inch Firestone Wilderness AT tires. Dealers should immediately
order replacement tires for inventory.
^ Certified Tire Dealers will order replacement tires through normal channels.
^ Dealers not authorized for the Around the Wheel Program will not participate in this recall.
Dealers may call the Ford Tire Hotline 1-888-353-3251 for enrollment and program details.
TIRE AVAILABILITY:
All dealers should check QCDealer.com daily for updates to the approved tires list. Distributors and
tire retailers will allocate tires as best they can on a daily basis. Your dealership should do the
following to ensure that you are able to secure your fair allotment of these limited volumes:
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8749
^ Contact your Ford authorized facing distributor(s) for each tire manufacturer.
^ Contact your Ford authorized facing tire retailers for each tire manufacturer.
^ Review with these supply points the volume of tires you need to ensure you have tires ready to fill
orders with every supply point.
Questions not addressed by above sources should be directed to your market area team.
CUSTOMER WAIT LISTS:
Dealers should create a customer wait list and record: Customer name
^ Address and phone number
^ Vehicle make
^ Model year
^ Mileage
^ Tire size
NOTE:
Customers should be prioritized to replace oldest tires first.
WAIT LIST SURVEY
Please fill out the Firestone Tire Survey in the Management Report Section of QCDealer weekly. It
is critical that you answer the questions as accurately as possible as the survey results will be used
to help determine the level of production from the tire manufacturers.
DEALER PRICE
For latest prices on replacement tires, refer to the most recent Ford Motor Company Tire Price List.
PROCEDURE FOR CLAIMING REFUNDS FOR TIRES PURCHASED AFTER NOVEMBER 15,
2001
The following procedure applies to tires purchased after November 15, 2001:
1. Determine if the customer should receive special consideration based on owner loyalty, special
circumstance cc, etc.
2. If the customer is eligible for special consideration the dealer will call the Special Service
Support Center at 1800-325-5621 to request an authorization code.
3. The Special Service Support Center representative will ask for the following:
^ Customer Name
^ VIN
^ Date of repair
^ Original copy of invoice (be prepared to fax)
4. If the customer qualifies for a refund, the Special Service Support Center will provide your dealer
with an authorization code.
5. Your dealer will input a claim with the authorization code (authorization code must be included to
receive payment).
6. After the dealer receives payment for the claim, the dealer will then send the refund to the
customer.
NOTE:
If the Special Service Support Center determines that the customer does not qualify for a refund,
no authorization code will be given. Any appeals must be made by the dealer to the appropriate
field representative
Attachment III - Technical Information
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 01B77 > Oct > 01 > Recall - Firestone Tire Recall Supplement >
Page 8750
AFFECTED VEHICLES: REFER TO DEALER LETTER FOR AFFECTED TIRES AND VEHICLES
OVERVIEW
This program details the replacement of 15-, 16-, and 17-inch Firestone Wilderness AT tires
regardless of production plant. You will need to perform a DOT code inspection prior to replacing
the 15, 16, or 17-inch Wilderness AT tires.
NOTE:
When lowering or raising an under-vehicle spare, DO NOT use power tools. Also make sure that
the spare is secure under the vehicle, and not swinging loose. The spare tire winch will ratchet
when the tire is completely stowed.
NOTE:
Radial ATX "TEMPORARY USE" spare tires are not included under this program, and should not
be replaced as part of this program.
NOTE:
Spare tires should always be replaced with the exact same size tire; otherwise the spare tire may
not store in the proper position on the vehicle.
INSPECTION
1. Inspect the vehicle tires (including the spare tire) for the presence of Firestone Wilderness AT
tires.
2. If Firestone Wilderness AT tires are present replace them with a suitable replacement from the
"Approved Tire List".
Note:
There may be cases where a vehicle is equipped with 15-, 16-, or 17-inch Firestone Wilderness AT
tire sizes that are not included on the Ford-approved replacement list. These tires are not original
equipment (OE) and, therefore, will not have an approved tire listed. In such cases, it is
recommended that the customer install the proper OE tire, or have a tire of suitable quality
installed. Reference the vehicle's "Safety Certification Label" and current "Ford Motor Company
Tire Price Guide" for OE or suitable replacement recommendations.
3. If only one Firestone Wilderness AT road tire is present on the vehicle, you will need to replace
the opposing tire on the same axle. However, if one (1) front and one (1) rear tire are Wilderness
AT you would not automatically replace all four (4) tires instead, you would replace the two (2)
Wilderness AT tires and place them on the same axle.
4. Record the DOT code from each removed tire(s) on the repair order.
5. Tires that are removed from vehicles must immediately be made unusable by either cutting
through the bead and DOT code with bolt cutters, or drilling a one-inch diameter hole (directly on
the DOT code to make the code unreadable) in the sidewall.
6. Adjust all tires to the proper inflation pressure, and release the vehicle. For specifications, refer
to the vehicle Owner's Manual or the vehicle certification label located on the driver's door opening.
NOTE:
Tires that are removed from vehicles under this program, and those in dealer inventory must
immediately be made unusable by either cutting the bead with bolt cutters or drilling a 1" diameter
hole (directly on the DOT code to make the code unreadable) in the sidewall. Defacing the DOT
code will prevent the tire from being used for an additional refund request.
NOTE:
If the vehicle is a 4X4, and is equipped with non-Firestone Wilderness AT tires on one axle, and the
replacement tires for the Firestone equipped axle causes a mismatch with the existing
non-Firestone axle, the customer is responsible for the tire mismatch. If the customer refuses to
purchase matching tires to correct the mismatch - the dealer should annotate the repair order to
reflect the customer's decision.
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Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8755
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Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8756
Attachment I - Administrative Information
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Attachment II - Labor Information
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Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8757
LABOR ALLOWANCES
Attachment III - Technical Information
SPECIAL FIELD ACTION 00L12 WARRANTY GUIDE SUPPLEMENT
VEHICLES COVERED BY THE NEW TIRE WARRANTY All 2001 model year passenger cars and
light trucks up to and including F550 Super Duty vehicles sold in the U.S., U.S. Territories, Mexico,
and Canada, built through December 31, 2000.
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after December 31, 2000.
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (attached to this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
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Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8759
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8760
Supplement # 1 - Information
Supplement # 1, February 5, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
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Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8761
Attachment III ^
Technical Information
Customer Notification Letter
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Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8762
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Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8763
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Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8764
Supplement # 1 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 1 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8765
LABOR ALLOWANCES
Supplement # 1 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8766
SERVICE PROCEDURE
1. Obtain a copy of the Warranty Guide Supplement.
NOTE:
Beginning January 2001, dealers will begin to receive vehicle notification letters, which includes the
Warranty Guide Supplement, for in-stock units. In the interim, until notification letters begin to arrive
at the dealership, please make copies of the Warranty Guide Supplement (included in this
document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8767
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8768
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8769
Supplement # 2 - Information
Supplement # 2, February 19, 2001 - Updated Information
Cover Letter
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^Labor Allowances
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8770
Attachment III ^
Technical Information
Apology Letter
Customer Notification Letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8771
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8772
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8773
Supplement # 2 - Attachment I
OASIS
Will not be active for this program.
PLEASE NOTE
Correct all units in dealer inventory prior to delivery to the customer.
DEALER - OWNER CONTACT
An owner list will not be provided for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACES II manual for claims preparation and submission information.
Supplement # 2 - Attachment II
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8774
LABOR ALLOWANCES
Supplement # 2 - Attachment III
WARRANTY GUIDE SUPPLEMENT
NOTE:
Information regarding tire warranty will be included in the Warranty Guide for vehicles produced
after the end date listed above.
SERVICE PROCEDURE
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8775
1. Obtain a copy of the Warranty Guide Supplement. Note: Beginning January 2001, dealers will
begin to receive vehicle notification letters, which includes the Warranty Guide Supplement, for
in-stock units. In the interim, until notification letters begin to arrive at the dealership, please make
copies of the Warranty Guide Supplement (attached to this document).
2. Locate the vehicle Warranty Guide (located in the glove compartment).
3. Place a copy of the Warranty Guide Supplement in the Warranty Guide of the vehicle.
PLEASE NOTE:
This procedure is for dealer stock units only. Owners of vehicles previously delivered will receive a
copy of the Warranty Guide Supplement with their notification letter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8776
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8777
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L12 > Jan > 01 > Warranty - Guide Supplement > Page 8778
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification
Label Non-Compliance
Tires: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
Technical Service Bulletin # 00L09 Date: 000910
Information
00L09
SPECIAL FIELD ACTION
Certain 1991-2001 Explorer and 1997-2001 Mountaineer and 2001 Explorer Sport Trac and
Explorer 2-Door Sport Vehicles - Supplemental Tire Inflation Label
Dealer Letter
Attachment I ^
Administrative Information
Attachment II ^
Labor Allowances
^ Parts Ordering Information
Attachment III ^
Technical Information
Explorer/Mountaineer & Explorer 2-Door Sport owner letter
2001 Explorer Sport Trac owner letter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
> Page 8787
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
> Page 8788
Attachment I - Administrative Information
OASIS
OASIS will not be activated for this program.
PLEASE NOTE
Correct all vehicles in stock before delivery.
DEALER-OWNER CONTACT
An owner list will not be provided.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using DWE.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
> Page 8789
LABOR ALLOWANCES
PARTS REQUIREMENTS
Ordering Instructions for Additional Labels
The supplemental tire inflation labels for this program are being sent directly to customers of the
affected vehicles. Additional labels may be ordered by calling the Recall Hotline at 1-800-325-5621.
Inform the operator you are calling in regard to Special Field Action 00L09. Be prepared to provide
your name, address, dealer P & A code, and vehicle(s) you need label(s) for.
NOTE:
There are two different labels. Affected Explorer/Mountaineer and Explorer 2-Door Sport 1991
through 2001 model year label will have recommended pressure of 30 psi front and 30 psi rear.
Affected Explorer Sport Trac 2001 model year label will have 30 psi front and 35 psi rear.
DEALER PRICE
Dealers will not be charged for the supplemental safety certification labels ordered under this
program.
Attachment III - Technical Information
AFFECTED VEHICLES: CERTAIN 1991-2001 EXPLORER, 1997-2001 MOUNTAINEER AND
2001 EXPLORER SPORT TRAC AND EXPLORER 2-DOOR VEHICLES.
SERVICE PROCEDURE
1. Open the driver's door and clean the area of the door below the certification label using isopropyl
alcohol and a clean rag. Remove any non-permanent labels such as oil change labels, if
necessary. If any other permanent label is in this location, clean an area large enough to allow for
full adhesion of the label to the painted door surface as close to the certification label as possible.
2. Allow the area to dry.
3. Peel the backing off the new supplemental certification label and install it per the illustration.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
> Page 8790
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
> Page 8791
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
> Page 8792
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Tires: > 00L09 > Sep > 00 > Campaign - Supplemental Tire Inflation Label
> Page 8793
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Page 8794
Tires: Specifications
Tire Tread Depth P225/70R15 A/S 0.37 in
P235/75R15 A/T 0.42 in
P255/70R16 A/T 0.42 in
Maximum Radial Runount Aluminum 0.040 in
Steel 0.040 in
Maximum Lateral Runout Aluminum 0.040 in
Steel 0.040 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Page 8795
Tires: Service and Repair
Removal
1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel
bearings.
Note: To avoid damage or scratching to the center cap, place facing up when removed.
Loosen the lug nuts. 1
Remove the center cap.
2 With the weight of the vehicle on the wheels, loosen the lug nuts.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick
panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
3. Raise and support the vehicle.
4. Remove the wheel and tire assembly.
1 Remove the lug nuts.
2 Remove the wheel and tire assembly, using a side-to-side rocking motion.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug
nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
Clean the wheel hub mounting, surface and wheel pilot.
2. Install the tire and wheel assembly.
1 Position the tire and wheel assembly.
2 Install the lug trots hand-tight, then lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical
Service Bulletins > Page 8796
3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake
roughness, shudder and vibration.
Tighten the lug nuts in a star pattern using a torque wrench or torque sticks.
4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the center cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Recalls: > NHTSA00V313000 > Oct > 00 > Recall 00V313000: Certification Label Non-Compliance
Wheels: Recalls Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force
Measurement Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force
Measurement Equipment > Page 8810
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > NHTSA00V313000 > Oct > 00 > Recall 00V313000:
Certification Label Non-Compliance
Wheels: All Technical Service Bulletins Recall 00V313000: Certification Label Non-Compliance
Certain sport utility vehicles fail to comply with the requirements of Part 567.4, "Certification."
These vehicles were shipped from the assembly plant without Safety Certification Labels.
Incorrect tire inflation pressure could result in tire tread separation, increasing the risk of a crash.
Dealers will replace the certification labels. All vehicles were at dealerships and certification labels
were affixed to these units on October 9, 2000. This recall is 100% complete.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment
Technical Service Bulletin # 02-1-6 Date: 020121
Wheels/Tires - Road Force Measurement Equipment
Article No. 02-1-6
01/21/02
^ WHEELS - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE TIPS
^ VIBRATION - ROAD FORCE MEASUREMENT EQUIPMENT HUNTER G5P9700 - SERVICE
TIPS
FORD: 1997 THUNDERBIRD 1997-2000 CONTOUR 1997-2002 CROWN VICTORIA, ESCORT,
MUSTANG, TAURUS 2000-2002 FOCUS 2002 THUNDERBIRD 1997-2002 E SERIES,
EXPEDITION, EXPLORER, F-150, RANGER, WINDSTAR 1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:
1997-1998 MARK VIII 1997-2002 CONTINENTAL, TOWN CAR 2000-2002 LS 1998-2002
NAVIGATOR 2002 BLACKWOOD
MERCURY: 1997 COUGAR 1997-2000 MYSTIQUE 1997-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR 1997-2002 MOUNTAINEER, VILLAGER
ISSUE The purpose of this bulletin is to provide guidance when using tire/wheel assembly road
force measurement equipment such as the Hunter GSP97OO. This bulletin is authored and
endorsed by Hunter, Michelin, Goodyear, Continental/General, Hankook, Bridgestone/Firestone
and Pirelli. Items addressed are software upgrades, road test (exercise tires), assembly center
verification and warranty restrictions.
This type of equipment can be a valuable tool to improve customer satisfaction when used as a
vibration repair tool. This type of equipment can also provide a high level of customer satisfaction
when used as an assembly too! when the customer has purchased new wheels/tires in the
"Around-the-Wheel" program.
ACTION The Hunter GSP9700/9712 road force measurement tool is NOT to be used for
determining if a tire or wheel meets a specification. It can be used as a service diagnostic tool to
minimize road force variation of the tire/wheel assembly. The tool such as the Hunter GSP97OO
can approximate the low point of the "'1heel and the high point of the tire. This allows the tire to be
matched mounted to the wheel for lowest tire/wheel assembly road force variation. This will
minimize the contribution to vibration from the tire/wheel assembly.
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 306000, 703000
Service Information
NOTE
TRADITIONAL WHEEL BALANCER "MATCH-MOUNTING" OR "WEIGHT OPTIMIZATION"
ACHIEVES WEIGHT MINIMIZATION AND WILL NOT ACHIEVE THE SAME RESULTS.
NOTE
WARRANTY CLAIMS CANNOT BE SUBMITTED FOR TIRE/WHEEL REPLACEMENT BASED ON
HUNTER G5P9700 RESULTS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Wheels: > 02-1-6 > Jan > 02 > Wheels/Tires - Road Force Measurement
Equipment > Page 8820
NOTE
UPGRADING SOFTWARE TO VERSION 2.1 OR GREATER WILL ENHANCE THE
TECHNICIANS CAPABILITY TO MINIMIZE THE ROAD FORCE VARIATION OF THE
TIRE/WHEEL ASSEMBLY. THE VERSION OF SOFTWARE CAN BE IDENTIFIED FROM THE
START-UP SCREEN BY PRESSING THE CENTER SHIFT KEY ONCE (I.E. HAS TWO GREEN
ARROWS) AND SELECTING THE K1 KEY ("IDENTIFY SOFTWARE"). IF THE SYSTEM IS IN
THE BALANCE MODE, THE START-UP SCREEN CAN BE ACCESSED BY PRESSING THE "R"
KEY TWICE (THIS IS JUST TO THE LEFT OF THE START KEY). CONTACT YOUR LOCAL
HUNTER ENGINEERING REPRESENTATIVE TO ORDER SOFTWARE UPGRADES.
1. Check the inflation pressure of all four tires and adjust to the vehicle manufacturers
recommended pressure. The vehicle manufacturers recommended tire pressure for the original
equipment tires can be found on the drivers side door placard.
2. Road test the vehicle on a smooth road for a minimum of 10 miles. Performance of the road test
at highway speeds is preferred.
NOTE
THIS MUST BE PERFORMED TO "EXERCISE" THE TIRES AND ELIMINATE "COLD" FLAT
SPOTTING THAT OCCURS DUE TO SHORT-PERIOD VEHICLE STORAGE OR PARKING. IF
THE VEHICLE'S TIRES ARE NOT EXERCISED FIRST, ACCURACY OF THE ROAD FORCE
MEASUREMENTS CAN VARY SIGNIFICANTLY, EVEN IF THE VEHICLE IS PARKED/STORED
IN ONE LOCATION FOR ONLY A SHORT PERIOD OF TIME (E.G. 20 MINUTES).
3. Perform the road force measurement IMMEDIATELY after exercising the tires. If the road force
measurement cannot be performed immediately, lift all four tires off the ground with a hoist or jack
stands to prevent measurement errors due to further flat spotting.
4. Assembly centering verification MUST be performed and PASSED prior to any road force
measurement.
For those with a software version other than 2.1 the centering verification must be performed
manually.
a. Spin assembly to measure. Record the assembly R1H.
b. Loosen wing-nut.
c. Rotate and reposition assembly and cone/adapter to a different mounting location (180 degrees).
d. Tighten wing-nut.
e. Re-spin to measure. Record the assembly R1H.
f. Compare results obtained in STEP a with those obtained in STEP e.
g. If the difference in assembly R1H measurements is less than 5 lbs., the assembly centering
verification PASSES and technician can proceed to the measurement/repair process. If the
centering verification FAILS proceed to STEP h.
h. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
5. For those with software version 2.1 the following procedure will lead the technician through a
Centering Check.
a. From the balance mode screen press the center SHIFT KEY ONCE (i.e. has two green arrows).
b. Push the "K1" button to select Perform Centering Check.
c. Follow the instructions.
d. If Centering Check PASSES proceed to the measurement/repair process. If the Centering Check
fails proceed to step e.
e. The following items may contribute to an assembly centering verification FAILURE.
^ Cone/adapter does not fit properly or is incorrect for the application
^ The wheel mounting surface is damaged
6. Prior to installing assembly on the vehicle balance assembly utilizing the two-plane dynamic
balancing mode.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Page 8821
Wheels: Specifications
Maximum Radial Runount Aluminum 0.045 in
Steel 0.045 in
Maximum Lateral Runout Aluminum 0.045 in
Steel 0.045 in
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Page 8822
Wheels: Description and Operation
WARNING: Do not mix different types of tires, such as radial, bias, or bias-belted, on the same
vehicle except in emergencies. Vehicle handling can be seriously affected and can result in loss of
control.
Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and
including full-rated load capacity when inflated to recommended inflation pressures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and
Repair > Wheel and Tire
Wheels: Service and Repair Wheel and Tire
Removal
1. CAUTION: Do not use heat to loosen a seized lug nut. Heat can damage the wheel and wheel
bearings.
Note: To avoid damage or scratching to the center cap, place facing up when removed.
Loosen the lug nuts. 1
Remove the center cap.
2 With the weight of the vehicle on the wheels, loosen the lug nuts.
2. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick
panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
3. Raise and support the vehicle.
4. Remove the wheel and tire assembly.
1 Remove the lug nuts.
2 Remove the wheel and tire assembly, using a side-to-side rocking motion.
Installation
1. WARNING: When a wheel is installed, always remove any corrosion, dirt or foreign material
present on the mounting surfaces of the
wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing
wheels without correct metal-to-metal contact at the wheel mounting surfaces can cause the lug
nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control.
Clean the wheel hub mounting, surface and wheel pilot.
2. Install the tire and wheel assembly.
1 Position the tire and wheel assembly.
2 Install the lug trots hand-tight, then lower the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and
Repair > Wheel and Tire > Page 8825
3. CAUTION: Failure to tighten the lug nuts in a star pattern can result in high brake disc runout,
which will speed up the development of brake
roughness, shudder and vibration.
Tighten the lug nuts in a star pattern using a torque wrench or torque sticks.
4. Note: If equipped with air suspension, reactivate the system by turning on the air suspension
switch.
Install the center cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and
Repair > Wheel and Tire > Page 8826
Wheels: Service and Repair Wheel Leaks
1. Pinhole leaks in cast aluminum wheels compromise wheel integrity. Install a new wheel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications
Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
Lubricate the lip of the new wheel bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Wheel Bearing Check
Wheel Bearing: Testing and Inspection Wheel Bearing Check
1. Raise and support the vehicle.
^ Make sure the system is warmed up to normal operating temperature, as thermal expansion can
be the cause of a strain problem.
WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT
OFF PRIOR TO HOISTING,JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN
BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH. FAILURE TO DO SO
CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH
CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.
2. Spin the tire by hand to check the wheel bearings for roughness.
NOTE: Make sure the wheel rotates freely and that the brake pads are retraced sufficiently to allow
free movement of the tire and wheel assembly.
3. Grip each front tire at the top and bottom arid move the wheel inward and outward while lifting
the weight of the tire off the front wheel bearing.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Wheel Bearing Check > Page 8832
4. If the tire and wheel (hub) is loose on the spindle, does not rotate freely, or has a rough feeling
when spun, carry out one of the following:
^ On vehicles with inner and outer bearings, inspect the bearings and cups for wear or damage.
Adjust or install new bearings and cups as necessary.
^ On vehicles with one sealed bearing, install a new wheel hub. Refer to the service procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Testing and Inspection > Wheel Bearing Check > Page 8833
Wheel Bearing: Testing and Inspection Wheel Bearing Inspection
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which
can result in shifting of the vehicle during these operations.
Raise the vehicle until the tire is off the floor.
2. Note: Make sure the wheel rotates freely and the brake pads are retracted sufficiently to allow
movement of the tire and wheel assembly.
Grasp each front tire at the top and bottom and move the wheel inward and outward while lifting the
weight of the tire off the front wheel bearing.
3. If the tire and wheel (hub) is loose on the wheel spindle or does not rotate freely, perform one of
the following actions.
^ On 4x2 vehicles, adjust the front wheel bearings.
^ On 4x4 vehicles, install a new wheel hub.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Solid Rear Axle
Wheel Bearing: Service and Repair Solid Rear Axle
Special Tools
Special Tools
Removal
1. Remove the axle shaft.
2. CAUTION: Never remove the wheel bearing oil seal by itself. Always remove the rear wheel
bearing and the inner wheel bearing oil seal at the
same time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Solid Rear Axle > Page 8836
Note: If the wheel bearing oil seal is leaking, the axle housing vent may be plugged with foreign
material.
Using the special tools, remove the rear wheel bearing and wheel bearing oil seal together.
Installation
1. Lubricate the new rear wheel bearing.
- For 4.0L SOHC and 4.0L EI with limited slip rear axles and 5.0L vehicles, use SAE 75W-140 High
Performance Rear Axle Lubricant F1TZ-19580-B or equivalent meeting Ford specification
WSL-M2C192-A.
- For 4.0L SOHC and 4.0L EI with conventional rear axles, use SAE 80W-90 Premium Rear Axle
Lubricant XY-80W90-QL or equivalent meeting Ford specification WSP-M2C197-A.
2. Using the special tools, install the rear wheel bearing. 3. Lubricate the lip of the new wheel
bearing oil seal.
- Use Premium Long-Life Grease XG-1-C or equivalent meeting Ford specification ESA-M1C75-B.
4. Using the special tools, install the wheel bearing oil seal. 5. Install the axle shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Service and Repair > Solid Rear Axle > Page 8837
Wheel Bearing: Service and Repair Independent Rear Suspension
Wheel Bearing
Removal And Installation
1. Remove the wheel knuckle.
2. CAUTION: Make sure that the press adapter outside diameter is slightly smaller than the hub
outside diameter or damage to the knuckle will
result.
Using a suitable press, remove the hub from the bearing.
- Discard the hub.
3. NOTE: The retainer ring is tapered and must be installed flat side down.
Remove the retainer ring.
- Discard the retainer ring.
4. Using a suitable press, remove the bearing from the wheel knuckle.
- Discard the bearing.
5. CAUTION: The hub and bearing cannot be reused after disassembly.
To install. reverse the removal Procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information
> Specifications
Axle Nut: Specifications
Wheel Hub Nut 157-213 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications
Wheel Fastener: Specifications
Wheel Nuts 135 Nm (100 lb/ft)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front
Wheel Fastener: Service and Repair Front
Removal
1. Raise the vehicle on a hoist. 2. Remove the wheel and tire assembly. 3. Remove the brake disc
and hub.
4. Using a suitable press, remove the wheel stud from the brake disc and hub.
Installation
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 8847
Wheel Fastener: Service and Repair Rear
Special Tool(s)
Special Service Tool(s)
Removal
CAUTION: Never use a hammer to remove the wheel stud. Damage to the axle flange, hub flange,
wheel bearing or hub bearing can result.
1. WARNING: The electrical power to the air suspension system must be shut off prior to hoisting,
jacking or towing an air suspension
vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack
storage area. Failure to do so can result in unexpected inflation or deflation of the air shocks, which
can result in shifting of the vehicle curing these operations.
Turn the air suspension service switch off, if so equipped.
2. Raise the vehicle and install safety stands. 3. Remove the wheel and tire assembly. 4. Remove
the rear disc brake caliper, rear disc support bracket and brake disc if so equipped. Support the
rear disc brake caliper with safety wire.
5. Using the C-Frame and Clamp Assembly Tool, press the wheel stud from its seat and discard.
Installation
CAUTION: Never use air tools to install wheel studs. The serrations can be stripped from the stud.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 8848
1. Insert a new wheel stud in the hole in the axle flange, making sure the serrations are aligned
with those made by the original wheel stud.
2. Seat new wheel studs in axle flange.
- Place four flat washers over the outside end of the wheel stud.
- Thread a standard wheel nut with the flat side against the washers.
- Tighten the wheel nut until the wheel stud head seats against the back side of the flange.
3. Remove the wheel nut and flat washers. 4. Install the brake disc, rear disc support bracket the
rear disc brake caliper, if so equipped. 5. Install the wheel and tire assembly. 6. Lower the vehicle.
7. Turn the air suspension service switch on, if so equipped.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications
Accumulator HVAC: Specifications
Accumulator To Evaporator Core Fitting 35-42 Nm
Suction/Accumulator Bracket Screws 6-8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 8853
Accumulator HVAC: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 8854
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 8855
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 8856
Accumulator HVAC: Service Precautions
CAUTION: Use a back-up wrench to prevent damage to the tubes.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 8857
Accumulator HVAC: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The suction accumulator/drier is mounted to the A/C accumulator bracket to the right of the vehicle
centerline. The inlet tube of the suction accumulator/drier attaches directly to the A/C evaporator
core outlet tube and the outlet tube attaches to the A/C manifold and tube.After entering the inlet of
the suction accumulator/drier, the heavier oil-laden refrigerant contacts an internally mounted dome
(which serves as an umbrella) and drips down onto the bottom of the canister.
- A small diameter oil bleed hole, in the bottom of the vapor return tube, allows the accumulated
heavier liquid refrigerant and oil mixture to re-enter the compressor suction line at a controlled rate.
As the heavier mixture passes through the small diameter liquid bleed hole, it has a second chance
to vaporize and recirculate through the A/C compressor without causing compressor damage due
to slugging.
- A fine mesh screened filter fits tightly around the bottom of the vapor return tube to filter out
refrigerant system contaminant particles.
- A desiccant bag is mounted inside the canister to absorb any moisture which may be in the
refrigerant system.
- A fitting located on the top of the suction accumulator/drier is used to attach the A/C cycling
switch. A long-travel Schrader-type valve stem core is installed in the fitting so that the A/C cycling
switch can be removed without discharging the A/C system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 8858
Accumulator HVAC: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the
Refrigerant Discharging and Recovery Procedure.
3. Disconnect the A/C cycling switch electrical connector.
4. Disconnect the suction accumulator/drier to A/C evaporator core fitting.
CAUTION: Use a back-up wrench to prevent damage to the tubes.
5. Disconnect the A/C manifold and tube spring lock coupling from the suction accumulator/drier
suction accumulator/drier.
6. Remove the suction accumulator/drier.
1 Remove the screw from the mounting bracket.
2 Lift the suction accumulator/drier out.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 8859
7. Transfer the A/C cycling switch to the new suction accumulator/drier.
INSTALLATION
1. To install, reverse the removal procedure.
- Service the new suction accumulator/drier with the correct amount of PAG compressor oil,
YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. See:
Refrigerant Oil Addition.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Specifications >
Page 8860
Accumulator HVAC: Tools and Equipment
Spring Lock Coupling Disconnect Tool Set
Spring Lock Coupling Disconnect Tool Set
Disconnect Tool, Spring Lock Coupling
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Service and
Repair
Air Conditioning Switch: Service and Repair
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations
Air Door Actuator / Motor: Locations
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Locations > Page 8868
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > With Manual A/C
W/O EATC
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > With Manual A/C > Page 8871
W/EATC
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Page 8872
Air Door Actuator / Motor: Service Precautions
CAUTION: Do Not attempt to bend any part of the lever. It is brittle and will break.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Diagrams > Page 8873
Air Door Actuator / Motor: Description and Operation
The A/C electric blend door actuator is located on the plenum assembly.
- its function is to move the air temperature blend door on command from the control assembly.
- The A/C electric blend door actuator contains a reversible electric motor and a potentiometer. The
potentiometer wiper is connected to the actuator output shaft and moves with the output shaft to
indicate the position of the air temperature blend door.
- A 5 volt signal is applied to the ends of the potentiometer. The voltage available at the wiper
indicates the position of the potentiometer. The expressed value of the actuator wiper voltage is
sent to the electronic automatic temperature control module and is matched with the wiper voltage
of the module potentiometer. The control module then drives the actuator motor in whichever
direction is necessary to make the actuator wiper voltage agree with the control module wiper
voltage.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor
Air Door Actuator / Motor: Service and Repair Blend Door Motor
REMOVAL
1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument
Panel : Service and Repair " See: Body
and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
2. Remove the A/C electronic door actuator motor.
- Remove the screws.
- Disconnect the harness connector and remove the A/C electronic door actuator motor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor > Page 8876
Air Door Actuator / Motor: Service and Repair Air Door Actuator / Motor, HVAC
Air Inlet Duct Door Vacuum Control Motor
REMOVAL
1. Release the stops and lower the glove compartment door to the floor.
2. Remove the screws and disconnect the vacuum hose.
3. Rotate the vacuum control motor.
CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break.
INSTALLATION
1. To install, reverse the removal procedure.
Panel/Defrost Door Vacuum Control Motor
REMOVAL
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor > Page 8877
1. Remove the screws and disconnect the vacuum hose.
2. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor.
CAUTION: Do not attempt to bend any part of the lever. It is brittle and will break.
INSTALLATION
1. To install, reverse the removal procedure.
Panel/Floor Door Vacuum Control Motor
REMOVAL
1. Remove the screws and disconnect the vacuum hose.
2. Rotate the vacuum control motor, disengage the lever, and remove the vacuum control motor.
CAUTION: Do Not attempt to bend any part of the lever. It is brittle and will break.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component
Information > Service and Repair > Blend Door Motor > Page 8878
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications
Air Duct: Specifications
Side Window Demister Hose And Nozzle Screws 2-3 Nm
Windshield Defroster Hose Nozzle Screws 2-3 Nm
Rear Floor Duct Screws 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Specifications > Page 8882
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct
Air Duct: Service and Repair Floor Duct
REMOVAL
1. Remove the console rear controls.
2. Remove the rear floor duct.
1. Remove the screws. 2. Remove the rear floor duct.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct > Page 8885
Air Duct: Service and Repair Windshield Defroster and Side Window Demister Nozzle
REMOVAL
1. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument
Panel, Service and Repair, Removal and
Installation See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair
2. Remove the two screws and remove the LH demister nozzle and duct.
3. Remove the two screws and remove the RH demister nozzle and duct.
4. Remove the screws and remove the windshield defroster hose nozzle.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Floor
Duct > Page 8886
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Specifications
Air Register: Specifications
LH Instrument Panel Register Screws 3.4-4.8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister
Air Register: Service and Repair Defrost Nozzles and Side Demister
REMOVAL
1. Remove the instrument panel. Refer to: " Body and Frame : Interior Trim : Dashboard/Instrument
Panel : Service and Repair " See: Body
and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
2. Remove the two screws and remove the LH demister nozzle and duct.
3. Remove the two screws and remove the RH demister nozzle and duct.
4. Remove the screws and remove the windshield defroster hose nozzle.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister > Page 8892
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister > Page 8893
Air Register: Service and Repair Air Register
Center
Radio Removing Tool
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Use the Radio Removing Tool to remove the radio chassis.
2. Disconnect the antenna lead and the wire harness connectors.
3. Remove the instrument panel finish panel.
1 Remove the screws.
2 Disengage the spring clips and remove the instrument panel finish panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister > Page 8894
4. Disconnect the wire harness connector.
5. Release the eight clips and remove the center instrument panel register from the instrument
panel finish panel.
INSTALLATION
1. Follow the removal procedure in reverse order.
Driver Side
REMOVAL
1. Remove the LH instrument panel finish panel; refer to Dash Board.
2. Remove the LH instrument panel register.
1 Remove the screws.
2 Remove the LH instrument panel register.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Defrost Nozzles and Side Demister > Page 8895
INSTALLATION
1. Follow the removal procedure in reverse order.
Passenger Side
REMOVAL
1. Lift the edge of the RH instrument panel register to expose the retainers.
2. Release the retainers and remove the RH instrument panel register.
INSTALLATION
1. Follow the removal procedure in reverse order.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair >
Page 8896
Radio Removing Tool
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 8900
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Locations > Page 8901
Ambient Temperature Sensor / Switch HVAC: Description and Operation
The A/C ambient air temperature sensor and bracket:
- is located in front of the A/C condenser core near the center of the vehicle.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the electronic automatic temperature control assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations
Blower Motor: Locations
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8905
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8906
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8907
Blower Motor: Description and Operation
The A/C blower motor pulls air from the air inlet and forces it into the plenum assembly where it is
mixed and distributed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8908
Blower Motor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the speed control servo.
1 Disconnect the electrical connector.
2 Remove the bolt.
3 Position the speed control servo aside.
3. Position the coolant/washer reservoir.
1 Remove the screws and the nuts.
2 Move the coolant/washer reservoir aside.
4. Remove the blower motor.
1 Disconnect the vent hose.
2 Disconnect the electrical connector.
3 Remove the four screws.
4 Remove the blower motor.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Locations > Page 8909
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Blower Motor Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Blower Motor Relay > Page 8914
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Blower Motor Relay > Page 8915
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Blower Motor Relay > Page 8916
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Page 8917
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Page 8918
Blower Motor Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations
Blower Motor Resistor: Locations
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 8922
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations >
Page 8923
Blower Motor Resistor: Description and Operation
The heater blower motor switch resistor has the following features:
- The assembly is located on the evaporator housing in the engine compartment.
- Three resistance elements are mounted on the resistor board to provide four blower motor
speeds.
- Depending on the heater blower motor switch position, series resistance is added or bypassed in
the blower motor circuit to decrease or increase blower motor speed.
- An overheating protective device (thermal limiter) will open the resistor coil circuit when the
temperature reaches 121°C (250°F) interrupting the blower motor operation in all speeds except
HIGH.
- The thermal limiter cannot be reset and is not serviceable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Service and Repair
Cabin Air Filter: Service and Repair
NOTE: The air distribution system of this vehicle cannot be equipped with a cabin air filter.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Cabin Temperature Sensor / Switch > Component Information >
Locations > Page 8933
Cabin Temperature Sensor / Switch: Description and Operation
The in-car temperature sensor operates in the following manner:
- A thermistor in the in-car temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the plenum
assembly and the in-car temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the plenum assembly air
stream to create a suction in the in-car temperature sensor.
- The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
Air Gap Between Pulley And Hub 0.35-0.85 mm
A/C Clutch Bolt 11-14 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8938
Compressor Clutch: Service Precautions
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8939
Compressor Clutch: Description and Operation
NOTE:
- Internal A/C compressor components are not serviced separately. The FS-10 A/C compressor is
serviced only as an assembly. The A/C clutch, A/C clutch pulley, A/C clutch field coil and the shaft
seal are serviceable.
- Installation of a new suction accumulator/drier is not required when repairing the air conditioning
system except when there is physical evidence of system contamination from a failed A/C
compressor or damage to the suction accumulator/drier.
Compressor Clutch Components
The magnetic A/C clutch has the following characteristics:
- It drives the compressor shaft.
- When battery positive voltage (B+) is applied to the A/C clutch field coil, the clutch disc and hub
assembly is drawn toward the A/C clutch pulley.
- The magnetic force locks the clutch disc and hub assembly and the A/C clutch pulley together as
one unit, causing the compressor shaft to rotate.
- When B+ is removed from the A/C clutch field coil, springs in the clutch disc and hub assembly
move the clutch plate away from the A/C clutch pulley.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8940
Compressor Clutch: Adjustments
1. Check the A/C clutch air gap at three equally spaced places between the clutch hub and the A/C
clutch pulley. 2. Remove the A/C clutch. Add or remove spacers between the A/C clutch and the
compressor shaft until clearance is within specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8941
Compressor Clutch: Service and Repair
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the A/C compressor.
2. Remove the bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8942
1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool.
2 Remove the bolt.
3. Remove the A/C clutch and the A/C clutch hub spacer.
1 Thread an 8 x 1.25 mm bolt into the A/C clutch to force it from the compressor shaft.
2 Lift the A/C clutch and the A/C clutch hub spacer from the compressor shaft.
4. Remove the pulley snap ring.
5. Remove the A/C clutch pulley.
6. Remove the A/C clutch field coil.
1 Note the location of the A/C clutch field coil electrical connector.
2 Install the Field Coil Remover on the nose opening of the A/C compressor.
3 Install the Puller-Differential Side Bearing.
4 Remove the A/C clutch field coil.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8943
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
INSTALLATION
1. Clean the A/C clutch field coil and pulley bearing mounting surfaces.
2. Install the A/C clutch field coil.
1 Place the A/C clutch field coil on the A/C compressor with the A/C clutch field coil electrical
connector properly positioned.
2 Place the Field Coil Replacer on the A/C clutch field coil.
3 Place the Coil Replacer on the Field Coil Replacer.
4 Use the 2-Jaw Puller to install the A/C clutch field coil until bottomed completely against the A/C
compressor.
CAUTION: Do not use air tools. The A/C clutch field coil can be easily damaged.
3. Install the A/C clutch pulley.
NOTE: The A/C clutch pulley is a tight fit on the A/C compressor head; it must be correctly aligned
during installation.
4. Install the pulley snap ring with the bevel side out.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8944
5. Place one nominal thickness A/C clutch hub spacer inside the clutch hub spline opening.
6. Install the A/C clutch.
7. Install the bolt.
1 Hold the A/C clutch hub with the Compressor Clutch Holding Tool.
2 Tighten the bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8945
Compressor Clutch Components
8. Measure and adjust the clutch air gap by removing or adding A/C clutch hub spacers. 9. Install
the A/C compressor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 8946
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Locations
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions
Compressor Shaft Seal: Service Precautions
CAUTION: Do not allow dirt or other foreign materials to enter the A/C compressor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8953
Compressor Shaft Seal: Service and Repair
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the A/C clutch from the A/C compressor.
2. Remove the shaft seal felt from the nose of the A/C compressor with the O-Ring Removal Pick.
3. Clean the compressor nose area.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8954
4. Insert the tip of the Snap Ring Remover into one of the snap ring eyes.
5. Rotate the Snap Ring Remover to position the tool tip and the snap ring eye closest to the A/C
compressor shaft.
6. Pull the Snap Ring Remover up quickly while keeping the tool shaft against the side of the nose
opening and remove the snap ring.
7. Engage the Compressor Seal Remover into the inside diameter of the shaft seal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8955
8. Turn the tool handle clockwise to expand the tool tip inside of the shaft seal.
9. Pull the seal from the A/C compressor.
INSTALLATION
1. Clean the A/C compressor nose area.
CAUTION: Do not allow dirt or other foreign materials to enter the A/C compressor.
2. Place the shaft seal on the seal protector. Lubricate the shaft seal and protector with PAG
compressor oil, YN-12-C, F7AZ-19589-DA or
equivalent meeting Ford specification WSH-M1C231-B.
3. Position the shaft seal and the Seal Protector over the A/C compressor shaft.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8956
4. Push the shaft seal onto the A/C compressor shaft with the Shaft Seal Replacer until seated.
5. Install the shaft seal snap ring. 6. Conduct the A/C compressor external leak test.
7. Install the shaft seal felt. 8. Install the A/C clutch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component
Information > Service Precautions > Page 8957
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Compressor Clutch Relay
Compressor Clutch Relay: Locations Compressor Clutch Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Compressor Clutch Relay > Page 8962
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Compressor Clutch Relay > Page 8963
Compressor Clutch Relay: Locations Compressor Cut-Off Relay
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Compressor Clutch Relay > Page 8964
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 8965
Compressor Clutch Relay: Description and Operation
WIDE OPEN THROTTLE A/C CUT-OFF
The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally
open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)).
If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant
temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C
(WAC) output, closing the relay contacts and sending voltage to the A/C clutch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations
> Page 8966
Compressor Clutch Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications
Compressor Fitting HVAC: Specifications
A/C Manifold Tube Bolt 17-23 Nm
A/C Manifold To Generator Clamp Nut 15-22 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications > Page 8970
Refrigeration System Components - 4.0L (5.0L Similar)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications > Page 8971
Compressor Fitting HVAC: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery. 2. Perform the
Refrigerant Discharging and Recovery Procedure.
3. Disconnect the A/C pressure cut-off switch connector.
4. Disconnect the A/C manifold and tube from the A/C condenser core.
5. Disconnect the A/C manifold and tube from the suction accumulator/drier.
6. Remove the bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications > Page 8972
7. Remove the nut. 8. Lift the A/C manifold and tube out of the vehicle.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the new O-ring seals with PAG Compressor Oil, YN-12-C, F7AZ-19589-DA or
equivalent meeting Ford specification WSH-M1C231-B.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications > Page 8973
Compressor Fitting HVAC: Tools and Equipment
Spring Lock Coupling Disconnect Tool (5/8 Inch)
Disconnect Tool, Spring Lock Coupling
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Compressor Fitting HVAC > Component Information >
Specifications > Page 8974
Special Tool(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications
Condenser HVAC: Specifications
A/C Line To Condenser Nut 6.8-9.2 Nm
A/C Condenser Core Bolt 8.4-11.2 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8978
Condenser HVAC: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8979
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8980
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8981
Condenser HVAC: Service Precautions
CAUTION: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8982
Condenser HVAC: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The A/C condenser core has the following characteristics:
- It is an aluminum fin and tube design heat exchanger located in front of the vehicle radiator.
- It cools compressed refrigerant gas by allowing air to pass over fins and tubes to extract heat and
by condensing gas to liquid refrigerant as it is cooled.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8983
Condenser HVAC: Testing and Inspection
On-Vehicle Leak Test
1. Perform the Refrigerant Discharging and Recovery Procedure. See: Service and
Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the suspect A/C evaporator
core or A/C condenser core from the A/C system.
NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the
core tubes.
3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling. See:
Coupler HVAC/Service and Repair/Spring Lock
Coupling Connect and Disconnect Procedure
4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to
the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a
Manifold (gauge Set to the test fittings on the A/C evaporator core or A/C condenser core.
Connect the yellow hose to a known good vacuum pump.
NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. if available, use hoses without shut-off valves. If hoses with shut-off valves are
used, make sure the valve opens when attached to the test fittings or install an adapter which will
activate the valve. The test is not valid if the shut-off valve does not open.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg)when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before installing a new A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101
kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8984
Condenser HVAC: Service and Repair
REMOVAL
CAUTION: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
NOTE: If an A/C condenser core leak is suspected, the A/C condenser core must be leak tested
before it is removed from the vehicle.
1. Perform the Refrigerant Discharging and Recovery Procedure.
2. Disconnect the A/C manifold and tube and the condenser to evaporator tube from the A/C
condenser core. 3. Remove the radiator. For additional information, refer to Cooling System.
4. Remove the condenser core bolt.
5. Squeeze to release the buckle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8985
6. Slide the A/C condenser out of the locators.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8986
1. To install, reverse the removal procedure.
- Service the replacement A/C condenser core with the correct amount of PAG compressor oil,
YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B. See:
Refrigerant Oil Addition.
- Lubricate new O-ring seals with PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
NOTE: When a new A/C condenser is installed, a new A/C evaporator core orifice should also be
installed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8987
Condenser HVAC: Tools and Equipment
Spring Lock Coupling Disconnect Tool Set
Spring Lock Coupling Disconnect Tool Set
Disconnect Tool, Spring Lock Coupling
Heater Hose Disconnect Tool
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications >
Page 8988
Special Tool(s)
Set, A/C Fittings
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
Control Assembly: Locations
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Page 8992
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Page 8993
Control Assembly: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations
> Page 8994
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > With Electronic Automatic Temperature Control (EATC)
Control Assembly: Description and Operation With Electronic Automatic Temperature Control
(EATC)
The Electronic Automatic Temperature Control (EATC) module, located in the instrument panel,
has the following features:
- 11 push buttons.
- a blower speed override thumbwheel for manual input.
- a vacuum fluorescent display for displaying set temperature, function and Diagnostic Trouble
Codes (DTCs).
- an On-Board Diagnostic (OBD) feature to supply the technician with Diagnostic Trouble Codes
(DTCs). These DTCs direct the technician to the inoperative component.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > With Electronic Automatic Temperature Control (EATC) > Page 8997
Control Assembly: Description and Operation With Manual A/C
The climate control assembly has three system controls:
- The A/C heater function selector switch combines a vacuum selector valve with two electrical
switches to supply battery positive voltage (B+) to the A/C clutch circuit and the blower motor
control circuit.
- The temperature selection is accomplished with a potentiometer connected to the electric blend
door actuator that controls positioning of the temperature blend door. Movement of the control knob
from COOL (blue) to WARM (red) causes a corresponding movement on the air temperature
control door and determines the temperature that the system will maintain.
- The blower motor switch controls blower motor speed by adding or bypassing resistors in the
heater blower motor switch resistor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Description
and Operation > Page 8998
Control Assembly: Testing and Inspection
For further information regarding this component please refer to :
Heating and Air Conditioning; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > With Electronic Automatic Temperature Control
Control Assembly: Service and Repair With Electronic Automatic Temperature Control
REMOVAL
1. Remove the radio chassis.
2. Remove the instrument panel finish panel.
1 Remove the screws.
2 Disengage the spring clips and remove the instrument panel finish panel.
3. Disconnect the connectors.
4. Remove the screws and remove the electronic automatic temperature control module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > With Electronic Automatic Temperature Control > Page 9001
5. Remove the electronic automatic temperature control module.
1 Disconnect the electrical connectors.
2 Remove the nuts.
3 Disconnect the vacuum harness connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > With Electronic Automatic Temperature Control > Page 9002
Control Assembly: Service and Repair Control Assembly Bulbs
REMOVAL
1. Remove the climate control assembly.
2. Turn and pull the lamp socket.
- Install a new the bulb in the socket.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > With Electronic Automatic Temperature Control > Page 9003
Control Assembly: Service and Repair With Manual Climate Control
REMOVAL
1. Remove the radio chassis. For additional information, refer to Radio,Stereo and Compact disc.
2. Remove the instrument panel finish panel.
1 Remove the screws.
2 Disengage the spring clips and remove the instrument panel finish panel.
3. Disconnect the connectors.
4. Remove the screws and remove the climate control assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > With Electronic Automatic Temperature Control > Page 9004
5. Disconnect the climate control assembly.
1 Disconnect the electrical connectors.
2 Disconnect the vacuum harness connector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts
Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts
Article No. 02-8-5
04/29/02
CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS
COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY
FORD: 1998-2001 EXPLORER
MERCURY: 1998-2001 MOUNTAINEER
ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature
Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a
steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the
FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software
version of the EATC Module.
ACTION Update the software version or replace the EATC Module. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE,
XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update
the EATC module software. On all other modules, replace the EATC module with service part
YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for
removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC
module ID number (Engineering Part Number).
NGS Procedure for Identifying EATC Module ID Number
1. Select "Diagnostics".
2. Select "EATC".
3. Select "Module I.D".
NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have
been previously updated with this software will display "GO7H-BA".
NGS Procedure for Updating Software
1. Select "Service Bay Functions".
2. Select "EATC" from module list.
3. Select "Module Configuration".
4. Select "99-01 Explorer" or "99-01 Mountaineer".
Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and
display "Module Data Download Successfull". If the EATC module has been updated previously, or
the module is not one of the modules listed as being capable of being updated, NGS will display
"Can not update with the NGS". If the module is not capable of being updated, replace the module
with part number YL2Z-19980-AA as listed above.
Parts Block
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 9013
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208000, 208100, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows
From Floor Ducts
Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts
Article No. 02-8-5
04/29/02
CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS
COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY
FORD: 1998-2001 EXPLORER
MERCURY: 1998-2001 MOUNTAINEER
ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature
Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a
steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the
FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software
version of the EATC Module.
ACTION Update the software version or replace the EATC Module. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE,
XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update
the EATC module software. On all other modules, replace the EATC module with service part
YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for
removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC
module ID number (Engineering Part Number).
NGS Procedure for Identifying EATC Module ID Number
1. Select "Diagnostics".
2. Select "EATC".
3. Select "Module I.D".
NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have
been previously updated with this software will display "GO7H-BA".
NGS Procedure for Updating Software
1. Select "Service Bay Functions".
2. Select "EATC" from module list.
3. Select "Module Configuration".
4. Select "99-01 Explorer" or "99-01 Mountaineer".
Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and
display "Module Data Download Successfull". If the EATC module has been updated previously, or
the module is not one of the modules listed as being capable of being updated, NGS will display
"Can not update with the NGS". If the module is not capable of being updated, replace the module
with part number YL2Z-19980-AA as listed above.
Parts Block
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows
From Floor Ducts > Page 9019
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208000, 208100, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control Blower Control Service Tips
Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service
Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control Blower Control Service Tips > Page 9024
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control Blower Control Service Tips > Page 9025
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower
Control Service Tips
Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service
Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower
Control Service Tips > Page 9031
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 > Oct > 00 > Climate Control - Blower
Control Service Tips > Page 9032
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Electronic Climate Control Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Electronic Climate Control Module > Page 9035
Control Module HVAC: Locations Blower Motor Speed Control
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations >
Electronic Climate Control Module > Page 9036
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Electronic Climate Control Module
Control Module HVAC: Diagrams Electronic Climate Control Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Electronic Climate Control Module > Page 9039
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Diagrams >
Page 9040
Control Module HVAC: Description and Operation
The blower speed control is located on the evaporator housing in the engine compartment.
- The function of the blower motor speed control is to convert low power signals from the electronic
automatic temperature control module to a high current, variable ground feed for the blower motor.
- The blower motor speed is infinitely variable and is controlled by the electronic automatic
temperature control module software.
- A delay function provides a gradual increase or decrease in blower motor speed under all
conditions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut
Fitting
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Peanut
Fitting > Page 9045
Spring Lock Coupling
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Diagrams > Page
9046
Coupler HVAC: Service Precautions
CAUTION:
- Do not use metal tools to remove the O-ring seals. They can cause axial scratches across the
O-ring seal grooves resulting in refrigerant leaks.
- Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring ; this can
cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks.
- Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent axial
scratches which may cause future leaks.
- Use only new green O-ring seals. The use of any O-ring seals other than specified may result in
intermittent leakage during vehicle operation.
- Support the female fitting with a wrench to prevent the tubes from twisting.
- Do not use metal tools to remove the O-ring seal. They can cause axial scratches across the
O-ring seal groove resulting in refrigerant leaks.
- Use only new green O-ring seals. The use of any O-ring seals other than specified may result in
intermittent leakage during vehicle operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and
Operation > Spring Lock Coupling
Coupler HVAC: Description and Operation Spring Lock Coupling
Spring Lock Coupling
The spring lock coupling is a refrigerant line coupling held together by a garter spring inside a
circular cage.
- When the coupling is connected together, the flared end of the female fitting slips behind the
garter spring inside the cage of the male fitting.
- The garter spring and cage then prevent the flared end of the female fitting from pulling out of the
cage.
- Three O-ring seals are used to seal between the two halves of the A/C condenser core couplings,
all other couplings have two O-ring seals.
- These O-ring seals are green in color and are made of special material.
- Use only the green O-ring seals listed in the Ford Master Parts Catalog for the spring lock
coupling.
- A plastic indicator ring is used on the spring lock couplings of the A/C evaporator core to indicate,
during vehicle assembly, that the coupling is connected. Once the coupling is connected, the
indicator ring is no longer necessary but will remain captive by the coupling near the cage opening.
- The indicator ring may also be used during service operations to indicate connection of the
coupling.
- An A/C tube lock coupling clip may be used to secure the coupling but is not required.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Description and
Operation > Spring Lock Coupling > Page 9049
Coupler HVAC: Description and Operation Peanut Fitting
The A/C condenser core uses the peanut shaped refrigerant fittings instead of spring lock
couplings.
- The male and female blocks of the peanut fitting are retained with a nut.
- An O-ring seal is installed around the tube on the male block.
- The female block is welded to the tube and is not adjustable.
- Support the female fitting with a wrench to prevent twisting of the tubes.
- The male block will pivot around the tube to allow for alignment with the female block during
assembly.
- When correctly assembled the male and female fittings should be flush.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure
Coupler HVAC: Service and Repair Spring Lock Coupling Connect and Disconnect Procedure
Spring Lock Coupling
SPECIAL SERVICE TOOL(S)
DISCONNECT
1. Remove the A/C tube lock coupling clip.
2. Fit the spring lock coupling disconnect tool to the spring lock coupling.
3. Push the tool into the cage opening to release the female fitting from the A/C tube lock coupling
spring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 9052
4. Pull the spring lock coupling fittings apart.
5. Remove the O-ring seals with a non-metallic tool.
- There are three O-ring seals required for the A/C condenser core couplings.
- There are two O-ring seals for all other refrigerant tube couplings.
CAUTION: Do not use metal tools to remove the O-ring seals. They can cause axial scratches
across the O-ring seal grooves resulting in refrigerant leaks.
6. Remove the A/C tube lock coupling spring with a small hooked wire.
CAUTION: Do not use a screwdriver or similar tool to remove the A/C tube lock coupling spring ;
this can cause axial scratches across the O-ring seal grooves resulting in refrigerant leaks.
CLEANING
1. Fabricate a cleaning tool from a 1/8 inch diameter brazing rod.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 9053
2. Cut an abrasive pad from maroon colored 3M Scotch Brite(R) with the dimensions
corresponding to the coupling size.
3. Assemble the pad to the tool. 4. Coat the abrasive pad with PAG Refrigerant Compressor Oil
(R-134a Systems) F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting
Ford specification WSH-M1C231-B.
5. Roll the pad on the tool and install it in a variable speed drill motor.
6. Polish for one minute at moderate speed (less than 1,500 rpm) or until the surface is clean and
free of scratches or foreign material.
CAUTION: Maintain low speed drill rotation when inserting or removing the cleaning tool to prevent
axial scratches which may cause future leaks.
7. Clean the fitting with a lint-free cloth. 8. Inspect the surface for grooves or scratches. If grooves
and scratches are still present, install a new component.
9. Clean the O-ring seal grooves with a 300 mm (12 inch) length of natural fiber string.
- Loop the string around the grooves and pull the string back and forth.
10. Remove any foreign material from the grooves with a lint-free cloth.
CONNECT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 9054
1. Install the A/C tube lock coupling spring.
2. Lubricate the inside of the coupling with PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-l2-C) or
equivalent meeting Ford specification WSH-MlC231-B.
3. Install the O-ring seals.
- Lubricate the O-ring seals with PAG Refrigerant Compressor Oil (R-134a Systems)
F7AZ-19589-DA (Motorcraft YN-12-C) or equivalent meeting Ford specification WSR-M1C231-B.
CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may
result in intermittent leakage during vehicle operation.
4. Connect the spring lock coupling fittings with a twisting motion until the A/C tube lock coupling
spring snaps over the flared end of the female
fitting.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 9055
5. Install the A/C tube lock coupling clip.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 9056
Coupler HVAC: Service and Repair Peanut Fitting Connect and Disconnect Procedure
DISCONNECT
1. Remove the nut from the peanut fitting.
CAUTION: Support the female fitting with a wrench to prevent the tubes from twisting.
2. Pull the peanut fitting apart.
3. Remove the O-ring seal with a non-metallic tool.
CAUTION: Do not use metal tools to remove the O-ring seal. They can cause axial scratches
across the O-ring seal groove resulting in refrigerant leaks.
CONNECT
1. Clean all dirt or foreign material from the fittings.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > Component Information > Service and Repair >
Spring Lock Coupling Connect and Disconnect Procedure > Page 9057
2. Install the O-ring seal.
- Lubricate the O-ring seal with PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B.
CAUTION: Use only new green O-ring seals. The use of any O-ring seals other than specified may
result in intermittent leakage during vehicle operation.
3. Lubricate the inside of the fittings with PAG compressor oil YN-12-C F7AZ-19589-DA or
equivalent meeting Ford specification
WSR-M1C231-B.
4. Assemble the male and female fittings together.
NOTE: When correctly assembled the male and female fittings should be flush.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
Evaporator Case: Service and Repair
REMOVAL
NOTE: The evaporator core is not separately serviceable, it is serviced only with the evaporator
core housing assembly. Replacement of the suction accumulator is not required when repairing the
refrigerant system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator. If an evaporator core leak is suspected, the
evaporator core must be leak tested before it is removed from the vehicle.
1. Remove the suction accumulator, please refer to Heating and Air Conditioning/ See:
Accumulator HVAC
2. Disconnect the blower motor and the blower motor resistor electrical connectors.
3. Detach the windshield wiper fluid hose. Using suitable hose pinching pliers, disconnect the
heater hoses.
4. Detach the heater control valve vacuum hose. 5. Disconnect the heater control valve vacuum
hose and the vacuum supply hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 9061
6. Disconnect the condenser to evaporator tube spring lock coupling.
7. Disconnect the vacuum harness connector. Remove the nut.
8. Remove two nuts, one bolt, and the A/C evaporator housing.
- Remove the nut located at the bottom of the A/C evaporator housing first.
- To remove the A/C evaporator housing, rotate the A/C evaporator housing counterclockwise.
Then tip the evaporator core end towards the front of the vehicle.
INSTALLATION
1. To install, reverse the removal procedure.
- Lubricate the refrigerant system with the correct amount of clean PAG Refrigerant Compressor
Oil (R-134a Systems) or equivalent. See: Refrigerant Oil Addition.
- Install new O-ring seals lubricated in amount of clean PAG Refrigerant Compressor Oil (R-134a
Systems) or equivalent.
- Lubricate the coolant hoses with MERPOL(R) or plain water only, if needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 9062
Evaporator Case: Tools and Equipment
Heater Hose Disconnect Tool
Spring Lock Coupling Disconnect Tool (5/8 Inch)
Disconnect Tool, Spring Lock Coupling
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Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and Repair
> Page 9063
Special Tool(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications
Evaporator Core: Specifications
Accumulator To Evaporator Core Fitting 35-42 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9067
Evaporator Core: Locations
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Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9068
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9069
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9070
Evaporator Core: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The A/C evaporator core is the plate/fin type with a unique refrigerant flow path.
- A mixture of refrigerant and oil enters the bottom of the A/C evaporator core through the A/C
evaporator core inlet tube and is routed so it flows through the partitioned first three plate/fin
sections.
- The next four plate/fin sections are partitioned to force the refrigerant to flow toward the other end
of the A/C evaporator core.
- Refrigerant then continues over to the remaining five plate/fin sections and then moves out of the
A/C evaporator core through the A/C evaporator core outlet tube.
- This S-pass flow pattern accelerates the flow of refrigerant and oil through the A/C evaporator
core.
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Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9071
Evaporator Core: Testing and Inspection
On-Vehicle Leak Test
1. Perform the Refrigerant Discharging and Recovery Procedure. See: Service and
Repair/Refrigerant Discharging and Recovery procedure 2. Disconnect the suspect A/C evaporator
core or A/C condenser core from the A/C system.
NOTE: DO NOT leak test an A/C evaporator core with the suction accumulator/drier attached to the
core tubes.
3. Clean the spring lock couplings. For additional information, refer to Spring Lock Coupling. See:
Coupler HVAC/Service and Repair/Spring Lock
Coupling Connect and Disconnect Procedure
4. Connect the appropriate test fittings from the R-12/R-134a Air Conditioning Test Fitting Set to
the evaporator or condenser tube connections. 5. Connect the red and blue hoses from the R-134a
Manifold (gauge Set to the test fittings on the A/C evaporator core or A/C condenser core.
Connect the yellow hose to a known good vacuum pump.
NOTE: The automatic shut-off valves on some gauge set hoses do not open when connected to
the test fittings. if available, use hoses without shut-off valves. If hoses with shut-off valves are
used, make sure the valve opens when attached to the test fittings or install an adapter which will
activate the valve. The test is not valid if the shut-off valve does not open.
6. Open both gauge set valves and start the vacuum pump. Allow the vacuum pump to operate for
a minimum of 45 minutes after the gauge set low
pressure gauge indicates 101 kPa (30 in-Hg). The 45 minute evacuation is necessary to remove
any refrigerant from oil left in the A/C evaporator core or A/C condenser core. If the refrigerant is
not completely removed from the oil, outgassing will degrade the vacuum and appear as a
refrigerant leak.
7. If the low pressure gauge reading will not drop to 101 kPa (30 in-Hg)when the valves on the
gauge and manifold set are open and the vacuum
pump is operating, close the gauge set valves and observe the low pressure gauge. If the pressure
rises rapidly to zero, a large leak is indicated. Recheck the test fitting connections and gauge set
connections before installing a new A/C evaporator core or A/C condenser core.
8. After evacuating for 45 minutes, close the gauge set valves and stop the vacuum pump.
Observe the low pressure gauge; it should remain at the
101 kPa (30 in-Hg) mark. If the low pressure gauge reading rises 34 or more kPa (10 or more in-Hg) of vacuum from the 101
kPa (30 in-Hg) position in 10 minutes, a leak is indicated.
- If a very small leak is suspected, wait 30 minutes and observe the vacuum gauge.
- If a small amount of vacuum is lost, operate the vacuum pump with gauge valves open for an
additional 30 minutes to remove any remaining refrigerant from the oil in the A/C evaporator core or
A/C condenser core. Then recheck for loss of vacuum.
- If a very small leak is suspected, allow the system to set overnight with vacuum applied and
check for vacuum loss.
9. If the A/C evaporator core or A/C condenser core does leak, as verified by the above procedure,
install a new A/C evaporator core or A/C
condenser core.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9072
Evaporator Core: Service and Repair
REMOVAL
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier. If an A/C evaporator core leak is
suspected, the A/C evaporator core must be leak tested before it is removed from the vehicle.
1. Disconnect the battery ground cable. 2. Perform the Refrigerant Discharging and Recovery
Procedure, please refer to Heating and Air Conditioning/Service and Repair/ See: Service and
Repair
3. Disconnect the A/C cycling switch.
4. Disconnect the electrical connectors.
1 Disconnect the A/C blower motor electrical connector.
2 Disconnect the A/C blower motor resistor electrical connector.
5. Disconnect the heater core.
1 Disconnect the heater water hoses.
2 Disconnect the heater water control valve vacuum hose.
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Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9073
6. Position the speed control servo aside.
1 Remove the (A) bolt and disconnect the (B) servo electrical connector.
2 Position the speed control servo aside.
7. Remove the nuts and the screws from the windshield washer reservoir/coolant recovery
reservoir. Set the reservoir aside.
8. Disconnect the A/C manifold and tube from the suction accumulator/drier.
9. Disconnect the condenser to evaporator tube.
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Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9074
10. Disconnect the (B) A/C system vacuum harness and the (A) A/C evaporator housing mounting
nut inside the vehicle.
11. Remove the A/C evaporator housing, please refer to Heating and Air Conditioning/Evaporator
Case/Service and Repair/ See: Evaporator
Case/Service and Repair 1
Remove the three underhood and one underdash nuts.
2 Lift the A/C evaporator housing out of the vehicle.
12. Disconnect the suction accumulator/drier from the A/C evaporator core.
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Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9075
13. Remove the screws attaching the housing cover.
14. Remove the A/C evaporator core.
1 Separate the evaporator case halves.
2 Lift the A/C evaporator core out.
INSTALLATION
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Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9076
1. To install, reverse the removal procedure.
- Service the new A/C evaporator core with the correct amount of PAG compressor oil, YN-12-C,
F7AZ-19589-DA or equivalent meeting Ford specification WSH-M1C231-B.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9077
Evaporator Core: Tools and Equipment
Spring Lock Coupling Disconnect Tool Set
Spring Lock Coupling Disconnect Tool Set
Disconnect Tool, Spring Lock Coupling
Heater Hose Disconnect Tool
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications >
Page 9078
Special Tool(s)
Set, A/C Fittings
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Locations > Page 9082
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Locations > Page 9083
Expansion Block/Orifice Tube: Description and Operation
A/C Evaporator Core Orifice
NOTE: A new A/C evaporator core orifice should be installed whenever a new A/C compressor is
installed.
The A/C evaporator core orifice has the following characteristics:
- It is color-coded red.
- It has an orifice diameter of 1.6 mm (0.062 inch).
- It is located in the A/C evaporator core inlet tube.
- It has filter screens located on the inlet and outlet ends of the tube body.
- The inlet filter screen acts as a strainer for the liquid refrigerant flowing through the A/C
evaporator core orifice.
- O-rings on the A/C evaporator core orifice prevent the high-pressure liquid refrigerant from
bypassing the A/C evaporator core orifice.
- Adjustment or service cannot be made to the A/C evaporator core orifice assembly. A new
evaporator core orifice assembly must be installed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Locations > Page 9084
Expansion Block/Orifice Tube: Service and Repair
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the condenser to evaporator tube.
2. Engage the Fixed Orifice Tube Tool to the A/C evaporator core orifice.
3. Hold the tool T-handle stationary and rotate the tool body to remove the A/C evaporator core
orifice.
4. To remove a broken A/C evaporator core orifice, screw the end of the Throttle Remover into the
broken A/C evaporator core orifice.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Locations > Page 9085
5. Hold the tool T-handle stationary and rotate the tool body to remove the broken A/C evaporator
core orifice.
INSTALLATION
1. Lubricate and install the O-ring seals on the A/C evaporator core orifice.
- Use PAG compressor oil, YN-12-C, F7AZ-19589-DA or equivalent meeting Ford specification
WSH-M1C231-B.
2. Place the A/C evaporator core orifice into the Fixed Orifice Tube Tool.
3. Insert the A/C evaporator core orifice into the condenser to evaporator tube until seated.
4. Remove the Fixed Orifice Tube Tool. 5. Install the condenser to evaporator tube.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information >
Locations > Page 9086
Expansion Block/Orifice Tube: Tools and Equipment
Spring Lock Coupling Disconnect Tool Set
Special Tool(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Locations
Expansion Valve: Locations
For further information regarding this component please refer to:
Heating and Air Conditioning; Expansion Block/Orifice Tube.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Core: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
9098
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Customer Interest for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
9099
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Core: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 9105
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Core: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 9106
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 9107
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 9108
Heater Core: Service Precautions
WARNING:
- CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS NECESSARY
TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS A GARAGE,
ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES OUTSIDE THE
CLOSED AREA.
THE HEATER CORE INLET HOSE WILL BECOME TOO HOT TO HANDLE IF THE SYSTEM IS
WORKING CORRECTLY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 9109
Heater Core: Description and Operation
The heater core consists of fins and tubes arranged to extract heat from the engine coolant and
transfer it to air passing through the heater core.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 9110
Heater Core: Testing and Inspection
WARNING: CARBON MONOXIDE IS COLORLESS, ODORLESS AND DANGEROUS. IF IT IS
NECESSARY TO OPERATE THE ENGINE WITH THE VEHICLE IN A CLOSED AREA SUCH AS
A GARAGE, ALWAYS USE AN EXHAUST COLLECTOR TO VENT THE EXHAUST GASES
OUTSIDE THE CLOSED AREA.
1. Inspect for evidence of coolant leakage at the heater water hose to heater core attachments. A
coolant leak in the heater water hose could follow
the heater core tube to the heater core and appear as a leak in the heater core.
NOTE: Testing of returned heater cores reveals that a large percentage of heater cores are good
and did not require installation of a new heater core. If a heater core leak is suspected, the heater
core must be tested by following the plugged heater core component test before the heater core
pressure test. Carry out a system inspection by checking the heater system thoroughly.
2. Check the integrity of the heater water hose clamps.
NOTE: Spring type clamps are installed as original equipment. Installation and overtightening of
non-specification clamps can cause leakage at the heater water hose connection and damage the
heater core.
Heater Core-Plugged
WARNING: THE HEATER CORE IN LET HOSE WILL BECOME TOO HOT TO HANDLE IF THE
SYSTEM IS WORKING CORRECTLY.
1. Check to see that the engine coolant is at the correct level. 2. Start the engine and turn on the
heater. 3. When the engine coolant reaches operating temperature, feel the heater core outlet hose
to see if it is hot.
If it is not hot. the heater core may have an air pocket
- the heater core may be plugged
- the thermostat is not working correctly.
Heater Core-Pressure Test Use Radiator/Heater Core Pressure Tester to carry out the pressure
test. 1. Drain the coolant from the cooling system. For additional information, refer to Cooling
system.
NOTE: Due to space limitations, a bench test may be necessary for pressure testing.
2. Disconnect the heater water hoses from the heater core. 3. Install a short piece of heater water
hose, approximately 101 mm (4 inches) long on each heater core tube.
4. Fill the heater core and heater water hoses with water and install Plug BT-7422-B and adapter
BT-7422-A from the radiator/heater core
pressure tester in the heater water hose ends. Secure the heater water hoses, plug and adapter
with hose clamps.
5. Attach the pump and gauge assembly from the Radiator/Heater Core Pressure Tester to the
adapter. 6. Close the bleed valve at the base of the gauge. Pump 241 kPa (35 psi) of air pressure
into the heater core. 7. Observe the pressure gauge for a minimum of three minutes. 8. If the
pressure drops, check the heater water hose connections to the core tubes for leaks. If the heater
water hoses do not leak, remove the
heater core from the vehicle and carry out the bench test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 9111
Heater Core-Bench Test 1. Remove the heater core from the vehicle. 2. Drain all of the coolant
from the heater core. 3. Connect the 101 mm (4 inch) test heater water hoses with plug and
adapter to the core tubes. Then connect the radiator/heater core pressure
tester to the adapter.
4. Apply 241 kPa (35 psi) of air pressure to the heater core. Submerge the heater core in water. 5.
If a leak is observed, install a new heater core.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 9112
Heater Core: Service and Repair
Heater Core Removal and Installation Procedures
Removal
Note: If a heater core leak is suspected, the heater core must be leak tested before it is removed
from the vehicle.
1. Drain the radiator.
2. Remove the heater water hose.
1. Squeeze the clamps and pull the hoses off. 2. Disconnect the vacuum hose from the water
control valve.
3. Remove the instrument panel. Refer to: Body and Frame, Interior Trim, Dashboard/Instrument
Panel, Service and Repair, Removal and
Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair
4. Remove the A/C evaporator core housing. 5. Remove the powertrain control module (PCM).
6. Remove the PCM heat sink.
1. Remove the ground strap screw. 2. Remove the heat sink.
7. Remove the heater air plenum nuts from the engine side of the dash panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service
Bulletins > Page 9113
8. Remove the heater core.
1. Remove the heater core cover to air plenum screws. 2. Lift off the cover.
9. Remove the heater core.
Installation
Note: Be sure to install a new oval foam seal around the heater core inlet and outlet tubes.
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications
Heater Core Case: Specifications
Plenum Chamber Nuts 3.4-4.8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Core Case > Component Information > Specifications >
Page 9117
Heater Core Case: Service and Repair
REMOVAL 1. Remove the dash board. Refer to: Body and Frame, Interior Trim,
Dashboard/Instrument Panel, Service and Repair, Removal and
Installation, See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service
and Repair
2. Drain the radiator. 3. Disconnect the heater hoses from the heater core.
4. Remove the evaporator core housing, please refer to Heating and Air Conditioning/Evaporator
Case/Service and Repair/ See: Evaporator
Case/Service and Repair
5. Remove the nuts and remove the plenum chamber.
INSTALLATION
1. Follow the removal procedure in reverse order.
- Lubricate the hoses and fittings with Rubber Suspension Insulator Lube E25Y-1 9553-A or
equivalent meeting Ford specification ESF-M99B112-A.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: All Technical Service Bulletins A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 9126
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
> Page 9127
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage
Heater Hose: Customer Interest A/C - Heater Core Electrolysis/Leakage
TSB 06-21-19
10/30/06
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)
FORD: 1997-2002 Contour 1997-2007 Crown Victoria, Mustang, Taurus 2000-2007 Focus
2002-2005 Thunderbird 2005-2007 Five Hundred, Freestyle 2006-2007 Fusion 1997-1999 F-250
Light Duty 1997-2003 Windstar 1997-2007 E-Series, Expedition, Explorer, F-150, F-53 Motorhome
Chassis, F-Super Duty, Ranger
2000-2005 Excursion 2001-2003 Explorer Sport 2001-2007 Escape, Explorer Sport Trac 2004
F-150 Heritage 2004-2007 Freestar 2005-2007 Escape Hybrid 1999-2007 F-650, F-750
LINCOLN: 1997-2002 Continental 1997-2007 Town Car 2000-2006 Lincoln LS 2006 Zephyr 2007
MKZ 1998-2007 Navigator 2002-2003 Blackwood 2003-2005 Aviator 2006-2007 Mark LT
MERCURY: 1997-2002 Cougar, Mystique 1997-2005 Sable 1997-2007 Grand Marquis 2005-2007
Montego 2006-2007 Milan 1997-2002 Villager 1997-2007 Mountaineer 2005-2007 Mariner
2006-2007 Mariner Hybrid
This article supersedes TSB 01-15-6 to update the vehicle model years and Service Procedure.
ISSUE The majority of repeat heater core leaks are due to high flow rate or use of poor quality
coolant. However, electrolysis should also be checked, especially when repeat repairs have
occurred.
ACTION If the heater core is leaking, review the location of the leakage and check the condition of
the coolant.
SERVICE PROCEDURE
1. Review the location of the leakage and check the condition of the coolant:
a. If leaks are found on the inlet (or outlet) tubes entering / exiting the heater core, it is most likely
due to due to high flow rate - replace the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
9133
heater core and install a restrictor in the heater hose closest to the engine block, reference
Workshop Manual, Section 412.
b. If leaks are found in the body of the heater core itself, and does not appear to be the result of
physical damage like contact or puncture, check the coolant for possible electrolysis.
Testing For Electrolysis
Check for voltage in the cooling system by touching the negative contact of a voltmeter to the
battery ground or a known good ground and suspend the positive lead in the coolant, making sure
it is in contact with the coolant but not touching any metal part of the radiator or cooling system.
Both AC and DC voltages must be checked. Vehicles normally have DC voltages; however, a faulty
engine block heater or faulty diode in the alternator can produce AC voltages. It is understood that
coolant is lost due to heater core failure but try to obtain a voltage reading on the old coolant in the
engine block before addition to or replacement of. To keep more coolant from exiting the heater
core clamp off heater core lines and measure coolant in the engine block. Try not to dilute the
original coolant with new coolant during testing if possible.
1. Determine whether coolant condition is acceptable.
a. Remove both cables from the battery and ensure they do not contact each other or the vehicle.
b. Touch negative lead of voltmeter to engine ground and positive lead in the coolant.
NOTE
POSITIVE TEST PROBE IS IN THE COOLANT FOR TESTING.
c. Check the voltage in the cooling system. If less than or equal to 0.4 volts (V) OK, reconnect
battery cables and proceed to Step 2.
d. If greater than 0.4 V, flush cooling system thoroughly.
e. Recheck voltage less than or equal to 0.4 V.
f. Reconnect battery cables.
g. Refill the system with appropriate Motorcraft® engine coolant.
2. Check for loose or missing grounds at static conditions.
a. Turn off all accessories. Turn ignition on but do not start engine.
b. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
c. Voltage less than or equal to 0.4 V on all grounds OK.
d. Any one greater than 0.4 V, check and clean ground cable connections.
e. Check accessories without using the on off switch on the vehicle instrument panel, use a jumper
wire to ground.
f. Plug in engine block heater, if equipped, and test.
g. Recheck voltage less than or equal to 0.4 V.
h. Unplug engine block heater, if equipped.
3. Check for loose, missing, or inadequate grounds.
a. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
b. Crank engine but do not start.
c. Monitor voltage while cranking. less than or equal to 0.4 V OK
d. If greater than 0.4 V, ground or repair starter.
e. Start engine and run at about 2000 rpm.
f. Turn on all accessories including those customer only uses occasionally such as CB radio, cell
phone, etc.
g. Test with ground probe to battery ground, engine ground, and vehicle ground sequentially.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Customer Interest for Heater Hose: > 06-21-19 > Oct > 06 > A/C - Heater Core Electrolysis/Leakage > Page
9134
h. Voltage less than or equal to 0.4 V OK
i. If greater than 0.4 V, turn off one item at a time until V drops to less than or equal to 0.4 V. Repair
ground to the accessory just identified.
j. Recheck voltage less than or equal to 0.4 V
k. Turn the DVOM to AC volts.
l. Check for ANY AC voltage greater than 0.4.
m. If any AC voltage is present then try turning off each accessory one at a time including blower
motor and any fan motors.
n. If AC voltage is still present then shut engine off and remove B+ from the alternator and tape it
up then retest.
o. If voltage drop is gradual to less than or equal to 0.4 V, the ground straps may simply be
overloaded by added accessories. Test by using heavy gauge jumper to ground. If indicated, install
heavier gauge ground strap(s) and recheck.
NOTE
If vehicle is equipped with electric cooling fans, be sure they cycle during this testing and monitor
voltage when they are on and when off.
CAUTION
DO NOT GROUND HEATER CORE. IF THE HEATER CORE IS GROUNDED, YOU HAVE
PROVIDED THE ELECTROLOSIS A PATH THROUGH THE HEATER CORE. THIS WOULD
CAUSE THE HEATER CORE TO BECOME AN ANODE OR RECEIVER AND IT WOULD
PROMOTE THE ELECTROLOSIS, OR ANY STRAY VOLTAGE TO USE THE COOLANT AS THE
GROUND PATH.
4. Refill the engine cooling system, reference Workshop Manual, Section 303-03.
NOTE
IF THE HEAT OUTPUT IS INSUFFICIENT, OR THE ENGINE DOES NOT REACH NORMAL
OPERATING TEMPERATURES, VERIFY PROPER THERMOSTAT OPERATION AND REPEAT
PROCEDURE IF REQUIRED.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
18476 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Page 9135
Heater Hose: Specifications
Heater hose bracket bolts 27 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Technical Service
Bulletins > Page 9136
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Specifications
High Pressure Safety Valve HVAC: Specifications
A/C Comprssor Pressure Relief valve 3103 kPa
Opening Pressure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Specifications > Page 9140
High Pressure Safety Valve HVAC: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Specifications > Page 9141
Refrigeration System Components - 4.0L (5.0L Similar)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Specifications > Page 9142
High Pressure Safety Valve HVAC: Description and Operation
An A/C compressor pressure relief valve is incorporated in the compressor A/C manifold and tube
to:
- relieve unusually high refrigerant system discharge pressure buildups, (3,103 kPa [450 psi] and
above).
- prevent damage to the A/C compressor and other system components.
- avoid total refrigerant loss by closing after the excessive pressure has been relieved.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications
Hose/Line HVAC: Specifications
Peanut Fitting Nut 7-9 Nm
A/C Line To Condenser Nut 6.8-9.2 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications >
Page 9146
Hose/Line HVAC: Description and Operation
NOTE: Installation of a new suction accumulator/drier is not required when repairing the air
conditioning system except when there is physical evidence of system contamination from a failed
A/C compressor or damage to the suction accumulator/drier.
The condenser to evaporator tube contains high pressure liquid refrigerant upstream of the A/C
evaporator core orifice.
The A/C manifold and tube is attached to the A/C compressor with O-ring seals and has the
following features:
- The upstream side contains low pressure refrigerant gas.
- The downstream side contains high pressure refrigerant gas and a fitting used to mount a
serviceable high-pressure A/C charge port valve.
- The downstream side also contains a fitting used to mount the A/C pressure cut-off switch. A
long-travel Schrader-type valve stem core is installed in the fitting so that the A/C pressure cut-off
switch can be removed without discharging the A/C system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications >
Page 9147
Hose/Line HVAC: Service and Repair
REMOVAL
1. Perform the Refrigerant Discharging and Recovery Procedure.
2. Disconnect the condenser to evaporator tube from the A/C condenser core.
3. Disconnect the condenser to evaporator tube spring lock coupling from the A/C evaporator core
and remove the condenser to evaporator tube.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Specifications >
Page 9148
Spring Lock Coupling
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Locations
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and
Operation
Receiver Dryer: Description and Operation
For further information regarding this component and the system that it is part of, please refer to:
Accumulator HVAC.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Description and
Operation > Page 9155
Receiver Dryer: Service and Repair
For further information regarding this component and the system that it is part of, please refer to:
Accumulator HVAC.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
System Capacity 30 oz (US)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 9160
Refrigerant: Fluid Type Specifications
Refrigerant Type Ford YN-19 (R-134a)
Specification WSH-M17B19-A
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
9161
Refrigerant: Service Precautions
The Ozone Layer A thin layer of ozone molecules, located 10 to 30 miles above the earth, form a
protective cover by absorbing a portion of the ultraviolet (UV) radiation emitted from the Sun.
Ozone Depletion Scientific research performed over the past 15 years links the release of
chlorofluorocarbons (CFC)s, also know by the trade name Freon) into the atmosphere to ozone
depletion. When CFCs are released into the atmosphere, they eventually reach the ozone layer
located in the stratosphere where they react with and destroy ozone molecules.
Harmful Effects Ozone depletion and the corresponding increase in UV radiation has been shown
to lead to higher incidents of cancer as well as global warming. When viewed from a global
perspective, ozone depletion holds an enormous potential for damage.
Upper Level Vs. Ground Level Ozone Confusion often arises when we hear about the necessity of
the ozone layer and ground level ozone. The ozone layer existing high above the earth is beneficial
but the same compound, when located at ground level, is harmful to humans, animals, crops and
vegetation.
Ground level ozone is a component of smog and forms when hydrocarbons (HC) react with
nitrogen oxides (NOx) in the presence of sunlight and heat.
Montreal Protocol In response to the growing body of evidence demonstrating the detrimental
effects of (CFC)s, 24 countries and the European community met in Montreal, Canada, in 1987 to
establish standards for the control of (CFC)s. Since that time, a total of 132 countries have become
signatories to this agreement leading to an end of production of R12 in December, 1995, in all
developed countries.
As established by the Montreal Protocol, R12 production in developed countries has ceased.
Clean Air Act The United States Congress, acting in response to the Montreal Protocol, banned
production of (CFC)s by the year 2000. Congress also amended the Clean Air Act in an effort to
control both the production and use of (CFC)s for refrigerant applications including mobile vehicle
air conditioning systems.
Additional Information Sources
For more complete and detailed explanations of the above policies, please refer to:
http://www.epa.gov/ozone/
Technician Certification Organizations providing technician refrigerant recovery and recycling
certification include:
National Institute for Automotive Service Excellence (ASE) 13505 Dulles Technology Drive, Suite 2
Herndon, VA 22071-3421 Phone: (703) 713-3800 Fax: (703) 713-0727 http://www.asecert.org/
International Mobile Air Conditioning Association (IMACA) P.O. Box 9000 Fort Worth, TX
76147-2000 Phone: (817) 732-4600 Fax: (817) 732-9610 http://www.imaca.org/
Mobile Air Conditioning Society (MACS) Worldwide P.O. Box 100 East Greenville, PA 18041
Phone: 215-679-2220
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
9162
Fax: 215-541-4635 http://www.macsw.org/
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
9163
Refrigerant: Service and Repair
SPECIAL SERVICE TOOL(S)
1. Prior to recovering the refrigerant system, you must verify the purity of the refrigerant. For
additional information, refer to Refrigerant
Identification Testing. See: Testing and Inspection/Component Tests and General
Diagnostics/Identifying Refrigerants
2. Connect the R-134a A/C refrigerant center to the low and high-pressure service gauge port
valves.
NOTE: Some R-134a service centers require the use of an A/C manifold gauge set. For additional
information, refer to Manifold Gauge Set Connection. See: Service and Repair/Manifold Gauge Set
Connection
3. Perform the Refrigerant Discharging and Recovery Procedure. 4. Once the refrigerant center
has recovered the vehicle A/C system refrigerant, close the refrigerant center inlet valve (if so
equipped). Then switch
off the power supply.
5. Allow the vehicle A/C system to remain closed for about two minutes. Observe the system
vacuum level as shown on the gauge. If the pressure
does not rise, disconnect the recovery station hose(s).
6. If the system pressure rises, repeat steps 2 through 5 until the vacuum level remains stable for
two minutes. 7. Carry out the required repairs, then Perform the Evacuation and Charging
Procedure. For additional information, refer to Evacuation and
Charging. See: Service and Repair/Evacuation and Charging Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
System Capacity 9 oz (US)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 9168
Refrigerant Oil: Fluid Type Specifications
Lubricant PAG Compressor Oil
Type YN-12c
Part Number F7AZ-19589-DA
Specification WSH-M1C231-B
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
9169
Refrigerant Oil: Service and Repair
CAUTION: During normal A/C operation, oil is circulated through the system with the refrigerant,
and small amount is retained in each component. If certain components of the system are
removed, some of the refrigerant oil will go with the component. To maintain the original total oil
charge, it is necessary to compensate for the oil lost by adding oil to the system with the new part.
1. Rotate the A/C compressor shaft six to eight revolutions while collecting oil in a clean measuring
device.
- If the amount of oil drained from the old A/C compressor is between 85-142 ml (3-5 ounces), pour
the same amount plus 30 ml (1 ounce) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or
equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is greater than 142 ml (5
ounces), pour the same amount drained of clean PAG compressor oil YN-12-C F7AZ-19589-DA or
equivalent meeting Ford specification WSH-M1C231-B into the new A/C compressor.
- If the amount of oil that was removed from the old A/C compressor is less than 85 ml (3 ounces),
pour 85 ml (3 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B into the new A/C compressor.
NOTE: Service A/C compressors are shipped without compressor oil.
2. For the suction accumulator/drier, drill two 1/2 inch holes in the suction accumulator/drier
cylinder and drain the oil into a calibrated container.
- Add a quantity of new oil to match that drained from the old suction accumulator/drier plus 60 ml
(2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent meeting Ford
specification WSH-M1C231-B.
3. For the A/C evaporator core, add 89 ml (3 ounces) of clean PAG compressor oil YN-12-C
F7AZ-19589-DA or equivalent meeting Ford
specification WSH-M1C231-B to the suction accumulator/drier inlet tube.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Page
9170
4. For the A/C condenser core , add 30 ml (1 ounce) of clean PAG compressor oil YN-12-C
F7AZ-19589-DA or equivalent meeting Ford
specification WSH-M1C231-B to the A/C condenser core or the suction accumulator/drier inlet
tube.
5. Add 60 ml (2 ounces) of clean PAG compressor oil YN-12-C F7AZ-19589-DA or equivalent
meeting Ford specification WSH-M1C231-B to the
suction accumulator/drier inlet tube when carrying out each of the following repairs: installation of a new A/C evaporator core orifice.
- installation of a new A/C compressor pressure relief valve.
- installation of a new refrigerant line.
- repair of an O-ring seal leak.
- repair of a charge port leak.
6. Installation of new components that do not require discharge of refrigerant and resulting oil loss,
such as the A/C cycling switch and the A/C
pressure transducer, do not require additional oil.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications
Refrigerant Pressure Sensor / Switch: Specifications
A/C Cycling Switch 324 kPa
Close Minimum
A/C Cycling Switch 152 kPa
Open Minimum
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Page 9174
Refrigerant Pressure Sensor / Switch: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Page 9175
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Page 9176
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Specifications > Page 9177
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
A/C Cycling Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction
accumulator/drier.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction pressure inside the suction accumulator/drier to control the operation of
the A/C cycling switch.
- The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi).
- The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi).
- When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the
wide open throttle A/C cutoff relay.
- When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of airflow.
- It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch > Page 9180
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch
PCM Inputs
AIR CONDITIONING CYCLING SWITCH
The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or
ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will
turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling
switch, refer to Heating and Air Conditioning.
The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when
the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch
and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are
closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle
specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See:
Powertrain Management/Description and Operation/PCM Outputs
NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C
is requested. This information is received by the PCM through the BUS + and BUS - Standard
Corporate Protocol (SCP) communication.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Description and Operation > A/C Cycling Switch > Page 9181
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure
Switch
Typical Air Conditioning Pressure Sensor
The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure
side of the A/C manifold and tube.
- A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch
contacts open, disengaging the A/C compressor.
- When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow
operation of the A/C compressor.
- It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay > Page 9187
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay > Page 9188
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Blower Motor Relay > Page 9189
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 9190
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Page 9191
Blower Motor Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Compressor Clutch Relay
Compressor Clutch Relay: Locations Compressor Clutch Relay
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Compressor Clutch Relay > Page 9196
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Compressor Clutch Relay > Page 9197
Compressor Clutch Relay: Locations Compressor Cut-Off Relay
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Compressor Clutch Relay > Page 9198
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 9199
Compressor Clutch Relay: Description and Operation
WIDE OPEN THROTTLE A/C CUT-OFF
The Wide Open Throttle A/C Cut-Off Relay (may be referred to as the A/C clutch relay) is normally
open. There is no direct electrical connection between the A/C switch or EATC Module and the A/C
clutch. The PCM will receive a signal indicating that A/C is requested (for some applications, this
message is sent through the BUS + and BUS - circuits). When A/C is requested, the PCM will
check other A/C related inputs that are available (such as ACP (SW), A/C Cycling Switch (ACCS)).
If these inputs indicate A/C operation is OK, and the engine conditions are OK (such as coolant
temperature, engine rpm, throttle position), the PCM will ground the Wide Open Throttle A/C
(WAC) output, closing the relay contacts and sending voltage to the A/C clutch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Page 9200
Compressor Clutch Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From
Floor Ducts
Control Module HVAC: Customer Interest A/C - Cold Air Blows From Floor Ducts
Article No. 02-8-5
04/29/02
CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS
COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY
FORD: 1998-2001 EXPLORER
MERCURY: 1998-2001 MOUNTAINEER
ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature
Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a
steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the
FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software
version of the EATC Module.
ACTION Update the software version or replace the EATC Module. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE,
XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update
the EATC module software. On all other modules, replace the EATC module with service part
YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for
removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC
module ID number (Engineering Part Number).
NGS Procedure for Identifying EATC Module ID Number
1. Select "Diagnostics".
2. Select "EATC".
3. Select "Module I.D".
NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have
been previously updated with this software will display "GO7H-BA".
NGS Procedure for Updating Software
1. Select "Service Bay Functions".
2. Select "EATC" from module list.
3. Select "Module Configuration".
4. Select "99-01 Explorer" or "99-01 Mountaineer".
Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and
display "Module Data Download Successfull". If the EATC module has been updated previously, or
the module is not one of the modules listed as being capable of being updated, NGS will display
"Can not update with the NGS". If the module is not capable of being updated, replace the module
with part number YL2Z-19980-AA as listed above.
Parts Block
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > Customer Interest: > 02-8-5 > Apr > 02 > A/C - Cold Air Blows From
Floor Ducts > Page 9209
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208000, 208100, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 >
Apr > 02 > A/C - Cold Air Blows From Floor Ducts
Control Module HVAC: All Technical Service Bulletins A/C - Cold Air Blows From Floor Ducts
Article No. 02-8-5
04/29/02
CLIMATE CONTROL - ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) BLOWS
COLD AIR FROM FLOOR DUCTS - VEHICLES PRODUCED BEFORE 9/30/2000 ONLY
FORD: 1998-2001 EXPLORER
MERCURY: 1998-2001 MOUNTAINEER
ISSUE Some vehicles produced before 9/30/2000 equipped with Electronic Automatic Temperature
Control (EATC) may blow cold air from the floor ducts after the climate control system reaches a
steady state in AUTO mode after switching from the FLOOR/DEFROST mode position to the
FLOOR mode position, usually after driving for 15-30 minutes. This may be caused by the software
version of the EATC Module.
ACTION Update the software version or replace the EATC Module. Refer to the following Service
Procedure for details.
SERVICE PROCEDURE
On vehicles equipped with the following EATC modules, F87H-18C612-BD, F87H-18C612-BE,
XL2H-18C612-AA, or XL2H-18C612-AB, use NGS with Service Card Version 9.0 or later to update
the EATC module software. On all other modules, replace the EATC module with service part
YL2Z-19980-AA. Refer to section 412-04 of the appropriate model year Workshop Manual for
removal and installation procedures. Use NGS with diagnostic card installed to verify the EATC
module ID number (Engineering Part Number).
NGS Procedure for Identifying EATC Module ID Number
1. Select "Diagnostics".
2. Select "EATC".
3. Select "Module I.D".
NGS will display the EATC module I.D. number (Engineering Part Number). Vehicles that have
been previously updated with this software will display "GO7H-BA".
NGS Procedure for Updating Software
1. Select "Service Bay Functions".
2. Select "EATC" from module list.
3. Select "Module Configuration".
4. Select "99-01 Explorer" or "99-01 Mountaineer".
Upon completion of the software upgrade, NGS will change the EATC module I.D to G07H-BA and
display "Module Data Download Successfull". If the EATC module has been updated previously, or
the module is not one of the modules listed as being capable of being updated, NGS will display
"Can not update with the NGS". If the module is not capable of being updated, replace the module
with part number YL2Z-19980-AA as listed above.
Parts Block
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 02-8-5 >
Apr > 02 > A/C - Cold Air Blows From Floor Ducts > Page 9215
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 208000, 208100, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3
> Oct > 00 > Climate Control - Blower Control Service Tips
Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service
Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3
> Oct > 00 > Climate Control - Blower Control Service Tips > Page 9220
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module HVAC: > 00-21-3
> Oct > 00 > Climate Control - Blower Control Service Tips > Page 9221
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 >
Oct > 00 > Climate Control - Blower Control Service Tips
Control Module HVAC: All Technical Service Bulletins Climate Control - Blower Control Service
Tips
Article No. 00-21-3
10/16/00
CLIMATE CONTROL - EATC - BLOWER MOTOR CONTROL SERVICE TIPS
FORD: 1990-1993 THUNDERBIRD 1990-2001 CROWN VICTORIA 1995-2001 EXPLORER
LINCOLN: 1990-2001 TOWN CAR 2000-2001 LS
MERCURY: 1990-1993 COUGAR 1990-2001 GRAND MARQUIS 1997-2001 MOUNTAINEER
ISSUE The following service procedure has been developed to aid technicians in diagnosing
EATC/DATC system blower motor control concerns.
ACTION Refer to the following Service Procedure as an aid in helping diagnose blower motor
control concerns.
SERVICE PROCEDURE
1. Check blower motor operation in all speeds.
^ If the blower motor does not operate in any speed, refer to Step 2.
^ If the blower motor continuously operates in HIGH, refer to the appropriate pinpoint test in the
Service/Workshop Manual.
^ If the blower motor does not operate in HIGH speed, refer to Step 3.
^ If the blower motor does not operate at speeds other than HIGH, refer to Step 4.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 >
Oct > 00 > Climate Control - Blower Control Service Tips > Page 9227
NOTE: REFER TO FIGURE 1 FOR CONNECTOR VIEW.
2. Refer to the appropriate pinpoint test in the Service/Workshop Manual, except for checking the
EATC/DATC module. When checking the
EATC/DATC module, set the blower motor speed to HIGH blower and measure the voltage
between the blower motor high blower relay circuit (Pin 3 at the controller) and ground at the
EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is 5 ohms or less,
repair the circuit. If the resistance is greater than 5 ohms, install a new EATC/DATC module
(19980). Retest the system for normal operation.
3. Set the blower speed control to HIGH and measure the voltage between the blower motor
control high blower relay circuit (Pin 3 at the controller)
and ground at the EATC/DATC module connector.
a. If the voltage is within 2 volts of battery voltage, measure the resistance between the blower
motor speed controller connector Pin 3 and the corresponding circuit/pin at the EATC/DATC
module connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for proper
operation.
b. If the voltage is more than 2 volts below battery voltage, measure the resistance between the
blower motor speed controller connector Pin 3 and ground. If the resistance is greater than 5 ohms,
install a new EATC/DATC module (19980). If the resistance is 5 ohms or less, repair the circuit.
Retest the system for normal operation.
4. Set the blower speed control to any speed other than HIGH and measure the voltage between
the blower motor control blower control circuit (Pin
2 at the controller) and ground at the EATC/DATC module.
a. If the voltage is below 1 volt, measure the resistance between the blower motor speed controller
connector Pin 1 and ground. If the resistance is greater than 5 ohms, install a new EATC/DATC
module (19980). If the resistance is 5 ohms or less, repair the circuit. Retest the system for normal
operation.
b. If the voltage is between 1 and 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 2 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less, install a new blower motor speed controller
(19E624). If the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
c. If the voltage is greater than 3 volts, measure the resistance of the circuit between the blower
motor speed controller connector Pin 1 and the corresponding pin at the EATC/DATC module
connector. If the resistance is 5 ohms or less; install a new blower motor speed controller
(19E624). If. the resistance is greater than 5 ohms, repair the circuit. Retest the system for normal
operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Control Module HVAC: > 00-21-3 >
Oct > 00 > Climate Control - Blower Control Service Tips > Page 9228
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 208000, 208300, 208999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Electronic Climate Control Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Electronic Climate Control Module > Page 9231
Control Module HVAC: Locations Blower Motor Speed Control
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Locations > Electronic Climate Control Module > Page 9232
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Electronic Climate Control Module
Control Module HVAC: Diagrams Electronic Climate Control Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Electronic Climate Control Module > Page 9235
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC >
Component Information > Diagrams > Page 9236
Control Module HVAC: Description and Operation
The blower speed control is located on the evaporator housing in the engine compartment.
- The function of the blower motor speed control is to convert low power signals from the electronic
automatic temperature control module to a high current, variable ground feed for the blower motor.
- The blower motor speed is infinitely variable and is controlled by the electronic automatic
temperature control module software.
- A delay function provides a gradual increase or decrease in blower motor speed under all
conditions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Service and Repair
Air Conditioning Switch: Service and Repair
REMOVAL
1. Remove the climate control assembly.
2. Remove the heater blower motor switch.
1 Remove the screw.
2 Rotate and remove the heater blower motor switch.
NOTE: The knob will come off when the switch is removed.
3. Remove the temperature control switch and the A/C damper door switch.
1 Remove the screw.
2 Rotate and remove the temperature control switch.
3 Rotate and remove the A/C damper door switch.
NOTE: The knobs will come off when the switch is removed.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations
Ambient Temperature Sensor / Switch HVAC: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 9244
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Locations > Page 9245
Ambient Temperature Sensor / Switch HVAC: Description and Operation
The A/C ambient air temperature sensor and bracket:
- is located in front of the A/C condenser core near the center of the vehicle.
- contains a thermistor which measures the temperature of outside air as a resistance and sends
that reading to the electronic automatic temperature control assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Cabin Temperature Sensor /
Switch > Component Information > Locations > Page 9252
Cabin Temperature Sensor / Switch: Description and Operation
The in-car temperature sensor operates in the following manner:
- A thermistor in the in-car temperature sensor measures air temperature inside the passenger
compartment.
- An automatic temperature control sensor hose and elbow is connected between the plenum
assembly and the in-car temperature sensor.
- The automatic temperature control sensor hose and elbow takes air from the plenum assembly air
stream to create a suction in the in-car temperature sensor.
- The suction draws in-vehicle air into the in-car temperature sensor and across the thermistor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications
Refrigerant Pressure Sensor / Switch: Specifications
A/C Cycling Switch 324 kPa
Close Minimum
A/C Cycling Switch 152 kPa
Open Minimum
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 9256
Refrigerant Pressure Sensor / Switch: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 9257
Manual A/C Electrical
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 9258
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Specifications > Page 9259
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch
Refrigerant Pressure Sensor / Switch: Description and Operation A/C Cycling Switch
A/C Cycling Switch
The A/C cycling switch is mounted on a Schrader valve-type fitting on the top of the suction
accumulator/drier.
- A valve depressor, located inside the threaded end of the A/C cycling switch, presses in on the
Schrader valve stem.
- This allows the suction pressure inside the suction accumulator/drier to control the operation of
the A/C cycling switch.
- The electrical switch contacts open when the suction pressure drops to 152-193 kPa (22-28 psi).
- The contacts close when the suction pressure rises to 276-324 kPa (40-47 psi).
- When the A/C cycling switch contacts close, the signal to energize the A/C clutch is sent to the
wide open throttle A/C cutoff relay.
- When the A/C cycling switch contacts open, the A/C clutch field coil is de-energized and
compressor operation stops.
- The A/C cycling switch will control the A/C evaporator core pressure at a point where the plate/fin
surface temperature will be maintained slightly above freezing.
- This prevents icing of the A/C evaporator core and blockage of airflow.
- It is not necessary to discharge the refrigerant system to remove the A/C cycling switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 9262
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning Cycling Switch
PCM Inputs
AIR CONDITIONING CYCLING SWITCH
The Air Conditioning (A/C) cycling switch may be wired to either the A/C Cycling Switch (ACCS) or
ACPSW Powertrain Control Module (PCM) input. When the A/C cycling switch opens, the PCM will
turn off the Air Conditioning (A/C) clutch For information on the specific function of the A/C cycling
switch, refer to Heating and Air Conditioning.
The A/C Cycling Switch (ACCS) circuit to the PCM provides a voltage signal which indicates when
the A/C is requested. When the A/C demand switch is turned on, and both the A/C cycling switch
and the high pressure contacts of the A/C high pressure switch (if equipped and in circuit) are
closed, voltage is supplied to the ACCS circuit at the PCM. Refer to Vehicle/Diagrams for vehicle
specific wiring.
If the ACCS signal is not received by the PCM, the PCM circuit will not allow the A/C to operate.
For additional information, refer to PCM outputs, wide open throttle air conditioning cutoff. See:
Powertrain Management/Description and Operation/PCM Outputs
NOTE: Some applications do not have a dedicated (separate) input to the PCM indicating that A/C
is requested. This information is received by the PCM through the BUS + and BUS - Standard
Corporate Protocol (SCP) communication.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Description and Operation > A/C Cycling Switch > Page 9263
Refrigerant Pressure Sensor / Switch: Description and Operation Air Conditioning High Pressure
Switch
Typical Air Conditioning Pressure Sensor
The A/C pressure cut-off switch is used to interrupt A/C compressor operation in the event of high
system discharge pressures.
- The A/C pressure cut-off switch is mounted on a Schrader valve-type fitting on the high pressure
side of the A/C manifold and tube.
- A valve depressor, located inside the threaded end of the A/C pressure cut-off switch, presses on
the Schrader valve stem.
- This allows the A/C pressure cut-off switch to monitor the compressor discharge pressure.
- When the compressor discharge pressure rises to approximately 2,896 kPa (420 psi), the switch
contacts open, disengaging the A/C compressor.
- When the pressure drops to approximately 1,724 kPa (250 psi), the contacts close to allow
operation of the A/C compressor.
- It is not necessary to discharge the refrigerant system to remove the A/C pressure cut-off switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations
Solar Sensor: Locations
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 9267
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 9268
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Solar Sensor, HVAC >
Component Information > Locations > Page 9269
Solar Sensor: Description and Operation
The A/C sunload sensor:
- is located on the top side of the instrument panel.
- contains a photovoltaic diode that is sensitive to light.
- has some unspecified resistance across the terminals depending upon the amount of light
reaching the photovoltaic diode; therefore the only test that can be performed is for an internal
short circuit.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations
Service Port HVAC: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page
9273
Refrigeration System Components - 4.0L (5.0L Similar)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Locations > Page
9274
Service Port HVAC: Description and Operation
The high-pressure service gauge port valve is located on the front A/C manifold and tube.
The low pressure service gauge port valve is located on the suction accumulator/drier.
The fitting is an integral part of the refrigeration line or component.
- Special couplings are required for both the high-side and low-side service gauge ports.
- A new Schrader-type valve core can be installed if the seal leaks.
- Always install the A/C charging valve cap on the service gauge port valve after repairing the
refrigerant system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations
Solar Sensor: Locations
Electronic Automatic Temperature Control Electrical Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 9278
Component Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 9279
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Solar Sensor, HVAC > Component Information > Locations >
Page 9280
Solar Sensor: Description and Operation
The A/C sunload sensor:
- is located on the top side of the instrument panel.
- contains a photovoltaic diode that is sensitive to light.
- has some unspecified resistance across the terminals depending upon the amount of light
reaching the photovoltaic diode; therefore the only test that can be performed is for an internal
short circuit.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Customer Safety Information
Vacuum Harness HVAC: Customer Safety Information
WARNING:
BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING
METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON
THE PRODUCT LABEL.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Customer Safety Information > Page 9285
Vacuum Harness HVAC: Technician Safety Information
WARNING:
BEFORE USING, OR HANDLING COMMERCIALLY AVAILABLE PAINT THINNER CONTAINING
METHYL ETHYL KETONE (MEK), READ AND FOLLOW THE WARNING INFORMATION ON
THE PRODUCT LABEL.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Page 9286
Vacuum Harness HVAC: Service and Repair
VACUUM HOSE REPAIR - MINI TUBE
Vacuum Pump Kit
SPECIAL SERVICE TOOL(S)
1. Measure the length of the damaged area of the mini-tube vacuum hose. 2. Cut a piece of
standard 1/8 inch inner diameter vacuum hose approximately 25 mm (1 inch) longer than the
damaged area of the mini-tube
vacuum hose.
3. Cut off the mini-tube vacuum hose on each side of the damaged area. 4. Dip the mini-tube hose
ends in commercially available paint thinner containing Methyl Ethyl Ketone (MEK). This solvent
will seal the mini-tube
in the vacuum hose.
WARNING: READ THE WARNING INFORMATION ON THE PRODUCT LABEL TO PREVENT
POSSIBLE INJURY.
5. Insert the ends of the mini-tube vacuum hose approximately 9 mm (3/8 inch) into the ends of the
standard 1/8 inch service vacuum hose section. 6. Shake the service joint after assembly to make
sure the solvent is dispersed and the vacuum line is not plugged. 7. Test the system for a vacuum
leak in the repair area.
- Use the Vacuum Tester or equivalent.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Harness HVAC > Component Information > Service
Precautions > Page 9287
Vacuum Tester Kit
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment
Repairs and Inspections Required After a Collision: Service and Repair Inspection and Repair After
A Supplemental Restraint System (SRS) Deployment
INSPECTION AND REPAIR AFTER A SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
DEPLOYMENT
WARNING: The restraint system diagnostic tool is for restraint system service only. Remove from
vehicle prior to road use. Failure to remove could result in injury and possible violation of vehicle
safety standards.
NOTE: After diagnosing or repairing a SRS the restraint system diagnostic tools must be removed
before operating the vehicle over the road.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
1. When any deployable device (driver air bag, passenger air bag, seat side air bag, safety belt
pretensioner, etc.) or combination of devices are
deployed and/or the ECS module has the DTC B1231 (Crash Data Memory Full) in memory, the
repair of the vehicle's supplemental restraint system (SRS) is to include the removal of all deployed
devices and installation of new deployable devices, the removal and installation of new impact
sensors, and the removal and installation of a new ECS module.
2. When any damage to the impact sensor mounting points or mounting hardware has occurred,
repair or install new mounting points and mounting
hardware as needed.
3. When the driver air bag module has deployed a new clockspring must be installed. 4. Inspect the
entire vehicle for damage, including the following components:
- steering column.
- instrument panel knee bolsters and mounting points.
- instrument panel braces and brackets.
- instrument panel and mounting points.
- seats and seat mounting points.
- safety belts, safety belt buckles, and safety belt retractors.
- Information.
- supplemental restraint system (SRS) wiring, wiring harnesses, and connectors.
5. After carrying out the review and inspection of the entire vehicle for damage, repair or install new
components as needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information >
Service and Repair > Inspection and Repair After A Supplemental Restraint System (SRS) Deployment > Page 9293
Repairs and Inspections Required After a Collision: Service and Repair Safety Belt Procedure After
A Collision
SAFETY BELT PROCEDURE AFTER A COLLISION
WARNING: All safety belt assemblies including retractors, buckles, front seat belt buckle support
assemblies (slide bar), shoulder belt height adjusters, child safety seat tether attachments (if
equipped), and attaching hardware should be inspected after any collision. New belt assemblies
should be installed unless a qualified technician finds the assemblies show no damage and operate
correctly. Belt assemblies not in use during a collision should also be inspected and replaced if
either damage or incorrect operation is noted.
NOTE: Safety belt assemblies should be periodically inspected to make sure they have not
become damaged and that they remain in correct operating condition, particularly if they have been
subjected to severe stress.
Before installing the new safety belt assembly, the safety belt attaching areas must be inspected
for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must
be reworked back to its original shape and structural integrity.
Install the new safety belt(s) using the appropriate instructions. Perform the Functional Test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: .
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 9299
7. Remove the two steering wheel back cover plugs.
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 9300
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 9301
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 9302
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 9303
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information
> Service and Repair > Air Bag Disarming and Arming > Page 9304
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Prove out the system means to turn the ignition switch from the OFF to the RUN position and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately six seconds and then turn off. If an air bag Supplemental
Restraint System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System - Air Bag
Lamp ON/DTC B1994/B1998
Air Bag Harness: Customer Interest Restraint System - Air Bag Lamp ON/DTC B1994/B1998
Article No. 03-24-1
12/08/03
ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994
AND/OR B1998
FORD: 1999-2001 EXPLORER SPORT, EXPLORER
MERCURY: 1999-2001 MOUNTAINEER
This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage.
ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit
an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998
stored in memory. This may be due to a high resistance or poor connections in the side air bag
(SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles
equipped with, or without, side air bags.
ACTION To service, install an overlay harness which incorporates soldered terminals and tin
wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation
instructions and illustrations are included in the kit.
SERVICE PROCEDURE
FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z"
1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction
sheet included in the kit.
FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D"
1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet
included in the kit.
^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB
^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC
^ 1999-2000 2DR Explorer XL2Z-14B455-BC
^ 2001 2DR Explorer 1L2Z-14B455-AC
Reference section 501-20A of the appropriate model year Workshop Manual for additional
information if needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > Customer Interest for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System - Air Bag
Lamp ON/DTC B1994/B1998 > Page 9314
Labor Operation Claiming Chart
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-01-10
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B455 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System Air Bag Lamp ON/DTC B1994/B1998
Air Bag Harness: All Technical Service Bulletins Restraint System - Air Bag Lamp ON/DTC
B1994/B1998
Article No. 03-24-1
12/08/03
ELECTRICAL - AIRBAG LAMP ILLUMINATED - DIAGNOSTIC TROUBLE CODES (DTC'S) B1994
AND/OR B1998
FORD: 1999-2001 EXPLORER SPORT, EXPLORER
MERCURY: 1999-2001 MOUNTAINEER
This article supersedes TSB 01-1-10 to update the model years and vehicle line coverage.
ISSUE Some 1999-2001 Explorer/Mountaineer 4DR and Explorer Sport 2DR vehicles may exhibit
an airbag lamp illuminated intermittently with diagnostic trouble codes (DTC's) B1994 or B1998
stored in memory. This may be due to a high resistance or poor connections in the side air bag
(SAB) wiring harness circuits or restraints control module. This condition may occur on vehicles
equipped with, or without, side air bags.
ACTION To service, install an overlay harness which incorporates soldered terminals and tin
wiring. Refer to the service procedure for direction on which side air bag kit to order. Installation
instructions and illustrations are included in the kit.
SERVICE PROCEDURE
FOR VEHICLES WITHOUT THE (SAB), FOURTH DIGIT OF VIN IS "Y" OR "Z"
1. Install a new Non-SAB wire harness kit 3L2Z-14B455-AB. Refer to the installation instruction
sheet included in the kit.
FOR VEHICLES EQUIPPED WITH (SAB), FOURTH DIGIT OF VIN IS "C" OR "D"
1. Install the appropriate harnesses as indicated below. Refer to the installation instruction sheet
included in the kit.
^ 1999-2001 4DR Limited Explorer XL2Z-14B455-DB
^ 1999-2001 4DR Explorer (except Limited) and Mountaineer XL2Z-14B455-AC
^ 1999-2000 2DR Explorer XL2Z-14B455-BC
^ 2001 2DR Explorer 1L2Z-14B455-AC
Reference section 501-20A of the appropriate model year Workshop Manual for additional
information if needed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Air Bag Harness: > 03-24-1 > Dec > 03 > Restraint System Air Bag Lamp ON/DTC B1994/B1998 > Page 9320
Labor Operation Claiming Chart
OTHER APPLICABLE ARTICLES: NONE
SUPERSEDES: 01-01-10
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14B455 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications
Air Bag Control Module: Specifications
Restraint Control Module Bracket 12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 9324
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 9325
Air Bag Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 9326
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Specifications > Page 9327
Air Bag Control Module: Description and Operation
The Restraints Control Module (RCM) carries out the following functions:
^ signals the inflators to deploy the air bags in the event of a deployable crash.
^ monitors the air bag Supplemental Restraint System (SRS) for faults.
^ illuminates the air bag indicator if a fault is detected.
^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic
Trouble Codes (DTCs).
^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safety sensor is internal to the RCM and is not serviced separately.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it
will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and
historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the
system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The
chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag
indicator require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors determine that a deployment is required. The backup power supply will deplete its
stored energy approximately one minute after the battery ground cable is disconnected.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Removal and Installation
Air Bag Control Module: Service and Repair Removal and Installation
REMOVAL
WARNING:
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT
COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the right hand cowl side trim panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Removal and Installation > Page 9330
3. Disconnect the Restraints Control Module (RCM).
1 Slide the two RCM electrical connector locking clips down to disengage them.
2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical
connectors.
4. Remove the RCM with bracket.
1 Remove the three RCM bracket retaining bolts.
2 Remove the RCM with bracket.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Removal and Installation > Page 9331
1. Follow the removal procedure in reverse order.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: A repair is made by installing a new part only. If the part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Removal and Installation > Page 9332
Air Bag Control Module: Service and Repair Weld Nut Repair
"J" Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both procedures before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld
nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control
Module (RCM), Front External Crash and Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification.
Stripped Weld Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Missing Weld Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Service and Repair > Removal and Installation > Page 9333
LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER
SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both procedures before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J"
Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts
must be installed as outlined in this procedure.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-5190).
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications
Clockspring Assembly / Spiral Cable: Specifications
Steering Column Fore And Aft Nuts 15 Nm
Lower Steering Column Opening Finish Panel Reinforcement 12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 9337
Clockspring Assembly / Spiral Cable: Diagrams
With Auxiliary Controls
Without Auxiliary Controls
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 9338
Clockspring Assembly / Spiral Cable: Description and Operation
The air bag sliding contact:
^ is mounted on the steering column, behind the steering wheel.
^ continuously transfers electrical signals from the driver air bag module to the Restraints Control
Module (RCM).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 9339
Clockspring Assembly / Spiral Cable: Service and Repair
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE AIR BAG MODULE DOWN WITH THE TRIM COVER FACE DOWN. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ AIR BAG MODULES WITH DISCOLORED OR DAMAGED TRIM COVERS MUST BE
REPLACED, NOT REPAINTED.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the driver air bag
module. 3. Remove the steering wheel.
NOTE: Make sure the wheels are in the straight-ahead position.
4. Apply two strips of masking tape across the air bag sliding contact to prevent accidental rotation
when the air bag sliding contact is removed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 9340
5. Remove the lower steering column opening finish panel.
1 Remove the retaining screws and position the hood release handle out of the way.
2 Remove the two retaining screws from the lower steering column opening finish panel.
3 Pull out to release the retaining clips and remove the lower steering column opening finish panel.
6. Remove the four retaining bolts and remove the lower steering column opening finish panel
reinforcement.
7. Loosen, but do not remove, the four steering column to instrument panel retaining bolts enough
to remove the upper steering column shroud (two
shown).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 9341
8. Remove the lower steering column shroud.
1 If equipped, remove the tilt wheel handle and shank.
2 Remove the three screws.
3 Remove the lower steering column shroud.
9. Remove the ignition switch lock cylinder.
1 Position the ignition switch lock cylinder to the RUN position.
2 Using the suitable tool, push upward on the cylinder release tab while pulling the ignition switch
lock cylinder outward.
10. Remove the upper steering column shroud.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 9342
11. Remove the Passive Anti-Theft System (PATS) transmitter.
1 Remove the PATS transmitter retaining screw.
2 Position the PATS transmitter out of the way.
12. Remove the key-in-ignition warning indicator switch.
13. Remove the two air bag sliding contact wire connectors from the wire connector bracket and
disconnect them.
14. Remove the wire harness from the two holders (one shown).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 9343
15. Release the lower air bag sliding contact retaining clip.
16. Remove the air bag sliding contact.
1 Release the remaining two air bag sliding contact retaining clips.
2 Remove the air bag sliding contact.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE AIR BAG MODULE WITH THE AIR BAG AND TRIM COVER POINTED AWAY
FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Specifications > Page 9344
1. Follow the removal procedure in reverse order. 2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information >
Specifications
Impact Sensor: Specifications
Side Crash Sensor 12 Nm
Front Crash Sensor 10.2-13.8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Driver Side Air Bag Crash Sensor
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Driver Side Air Bag Crash Sensor > Page 9350
Impact Sensor: Locations Front Crash Sensors
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Driver Side Air Bag Crash Sensor > Page 9351
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Driver Side Air Bag Crash Sensor > Page 9352
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations >
Driver Side Air Bag Crash Sensor > Page 9353
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front External Crash Sensor
Impact Sensor: Service and Repair Front External Crash Sensor
REMOVAL
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator grill
and radiator opening cover.
3. Remove the air bag sensor.
1 Disconnect the air bag sensor electrical connector.
2 Remove the three screws.
3 Remove the air bag sensor.
INSTALLATION
WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM
OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET
AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE
SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front External Crash Sensor > Page 9356
1. Follow the removal procedure in reverse order. 2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front External Crash Sensor > Page 9357
Impact Sensor: Service and Repair Side Crash Sensor
REMOVAL
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ Right side is shown, left side is similar.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the B-pillar lower trim panel with scuff plates.
NOTE: ^
Four door is shown, two door is similar.
^ The front seat has been removed for clarity.
3. Remove the side crash sensor.
1 Disconnect the side crash sensor electrical connector.
2 Remove the two retaining bolts.
3 Remove the side crash sensor with bracket.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and
Repair > Front External Crash Sensor > Page 9358
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS
CRITICAL FOR PROPER SYSTEM OPERATION.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Follow the removal procedure in reverse order. 2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Specifications
Side Air Bag: Specifications
AdjusterLatch/Pivot Cover Screw 1.6-2.2 Nm
Battery Ground Cable Bolt 7-10 Nm
Center Occupant Safety Belt Bolt 30-40 Nm
Driver Seat Module Screws 12 Nm
Front/Rear Seat Backrest Latch Bolts 47-63 Nm
Front Seat Back Pad Adjusting Pump Bolt 11-14 Nm
Front Seat Cushion Side Cover Screws 1.6-2.2 Nm
Front Seat Inboard Pivot Bolt 19-26 Nm
Front Seat Track To Floor Bolts 21-28 Nm
Inboard Safety Belt Bracket Bolt 38-44 Nm
Latch Handle Screws 1.6-2.2 Nm
Link Arm Nut 30-40 Nm
Rear Outboard Bolt 30-40 Nm
Rear Outboard Nut 30-40 Nm
Rear Seat Back Inboard/Outboard Pivot Bolts 38-44 Nm
Rear Seat Riser To Floor Nuts 30-40 Nm
Rear Seat Riser Pivot Bolts 38-44 Nm
Rear Seat Link Bolt 30-40 Nm
Rear Seat To Floor Bolts 30-40 Nm
Safety Belt Buckle Bracket To Floor Nuts 34-46 Nm
Seat Cushion To Adjuster Latch Bolts, Rear Seat 38-44 Nm
Seat Track To Seat Cushion Bolts 17-23 Nm
Side Air Bag Nuts 8 Nm
Slide Bar To Floor Bolt 40 Nm
Slide Bar To Seat Track Bolt 7.5-10.5 Nm
Slide Bar To Seat Track Nut 7.5-10.5 Nm
40% Seat Inboard Pivot Bolts 23-32 Nm
50% Seat Cushion To Seat Hinge Bolts 7-11 Nm
50/50 Seat Back Latch Bolt 30-46 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Specifications
> Page 9362
60% Front Seat Armrest Bolt 30-35 Nm
60% Seat Cushion Outboard Side Bolster Screw 1.6-2.2 Nm
60% Seat Inboard Pivot Cover Bolt 1.6-2.2 Nm
Side Air Bag Module 8 Nm
Seat Back Pivot Bolt 29 Nm
Seat Back Recliner Bolts 52 Nm
Track To Cushion Frame 20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Specifications
> Page 9363
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service
Precautions > Technician Safety Information
Side Air Bag: Technician Safety Information
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service
Precautions > Technician Safety Information > Page 9366
Side Air Bag: Vehicle Damage Warnings
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module
Side Air Bag: Service and Repair Side Air Bag Module
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON COVER TEAR SEAM. THIS WILL
REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARDS.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ When replacing the side air bag after deployment, refer to information concerning the installation
of a new side air bag.
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ Front driver seat is shown, passenger seat is similar.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the seat from the
vehicle.
WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE
AIR BAGS CANNOT BE REPAIRED; THEY ARE TO BE REPLACED (CLEANING IS
PERMISSIBLE).
3. Disconnect the seat motor electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9369
4. Remove the four bolts (two shown) and the seat track from the seat bottom.
5. Disconnect the power seat switch electrical connector.
6. Pull and remove the manual lumbar support adjustment handle and remove the lower seat trim
panel retaining screw.
NOTE: Release all tension from the manual lumbar support cable.
7. Press the tabs in on the two retaining clips (one shown) and separate the lower seat trim panel
from the seat bottom frame.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9370
8. Remove the lower seat trim panel.
1 Disconnect the heated seat switch (if equipped).
2 Remove the lower seat trim panel.
9. Remove the push pin holder from the seat bottom frame for the lumbar support cable.
10. Separate the lumbar support cable assembly.
1 Separate the lumbar support case assembly by sliding apart.
2 Remove the cable end ball from the cable end retainer and separate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9371
11. Remove the push pin retaining the heated seat back electrical connector to the seat bottom
frame.
12. Disconnect the heated seat back electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9372
13. Remove the side air bag electrical connector and wire harness push pins from the seat bottom
frame.
14. Remove the push pin from the side air bag electrical connector.
15. Remove the two retaining bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9373
16. Laying the seat on its other side, remove the retaining bolt for the seat pivot, being careful not
to damage the seat pivot, cable or any of the wires.
CAUTION: When positioning the seat or separating the seat bottom from the back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
17. Remove the seat back from the seat bottom.
1 Pull the heated seat wire harness through the seat bottom.
2 Pull the lumbar support cable through the seat bottom.
3 Pull the side air bag module wire harness through the seat bottom.
4 Remove the seat back from the seat bottom.
18. Separate the seat back trim cover lower J-clip.
19. Remove and discard the hog rings from the two swing rods (one shown).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9374
20. Slide the swing rods out of the seat back trim cover.
21. Roll the seat back trim cover, in an inside out fashion, to the side air bag deployment chute.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip. The
hook and loop strip can be torn from the seat cushion foam.
22. Unzip the side air bag deployment chute.
23. Roll the seat back cover and side air bag deployment chute to completely expose the side air
bag module and mounting bracket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9375
24. Remove the side air bag wire harness tie strap retainer.
25. Position the side air bag module aside, through the seat back cushion opening.
^ Remove the retaining nuts.
NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag
module is to be reused, then reuse the side air bag module retaining nuts.
26. Remove the side air bag module.
1 Slide the side air bag module electrical connector locking clip to disengage it.
2 Release the connector tabs by pushing in on them, then disconnect the side air bag module
electrical connector.
3 Remove the side air bag module.
INSTALLATION
WARNING:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9376
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Connect the side air bag module electrical connector.
1 Install the connector to the side air bag module.
2 Slide the side air bag module electrical connector locking clip to secure the connector to the side
air bag module.
2. Make sure the electrical connector is securely fastened to the side air bag module.
WARNING: ^
INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT
BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING
THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG
DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN
THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE
FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE
EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN
EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR
BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF
AN AIR BAG DEPLOYMENT.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE REPLACED AS A UNIT. FAILURE TO DO SO MAY RESULT
IN PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9377
3. Install the side air bag module onto the front seat back frame mounting bracket, making sure the
side air bag wiring harness is located behind the
seat backrest frame and side air bag module mounting bracket. 1
Position the side air bag module onto the front seat back mounting bracket.
2 Install the side air bag module retaining nut.
3 Install the side air bag module retaining nut.
4 Install the side air bag module retaining nut.
CAUTION: ^
The retaining nuts of the side air bag module must be tightened in the sequence described.
^ Make sure the side air bag wiring harness is not pinched between the side air bag module and
the mounting bracket.
4. Tie-strap the side air bag module wire harness to the seat back frame.
5. Unroll the seat back trim cover, to position the deployment chute around the side air bag module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9378
6. Position the air bag deployment chute.
1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side
air bag module, pulling it around the outboard side of the seat back frame.
2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side
air bag module from the inboard side of the seat back.
WARNING: ^
CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.
7. Zip the air bag deployment chute completely closed, then position the zipper tail at the top and
bottom of the deployment chute, into the seat back
opening. ^
The side air bag deployment chute must encircle the side air bag module, going completely around
the side air bag module and the side of the seat back frame.
^ Align the side air bag deployment chute to the side air bag module, making sure it covers the
length of the side air bag module.
NOTE: Be sure the side air bag deployment chute is properly positioned, before proceeding.
8. Unroll the seat back trim cover to the bottom row of hog rings.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9379
9. Install the swing rods back into the seat back trim cover sleeves.
10. Reaching between the seat back trim cover and the seat back pad, at the middle row of hog
rings, position the top of the swing rods under the
listing wire in the seat back pad.
NOTE: The seat back trim cover has been inverted for clarity.
11. Install new hog rings onto the swing rods (one shown). 12. Pull the seat back rest trim cover
completely down and connect the hook and loop fastener to the seat back cushion.
13. Route the seat back heating element wire harness (if equipped).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9380
14. Reattach the seat back trim cover lower J-clips.
15. Position the seat back to the seat bottom and route the wires and cables.
1 Pull the side air bag module wire harness through the seat bottom.
2 Pull the lumbar support cable through the seat bottom.
3 Pull the heated seat wire harness through the seat bottom.
16. Align the seat back to the seat bottom. Install the bolt and tighten to specification.
CAUTION: When positioning the seat or installing the bottom to the seat back, be careful not to
damage the seat back pivot and any of the wires or cables from the seat back to the seat bottom.
This can cause damage to one of the seat components.
17. Install the two bolts and tighten to specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9381
18. Install the push pin onto the side air bag electrical connector.
19. Route the side air bag module electrical connector and wire harness, then install the push pins.
20. Connect the heated seat wire connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9382
21. Route the heated seat wire harness and install the push pin.
22. Connect the lumbar support cable assembly.
1 Install the cable end ball to the cable end retainer.
2 Insert the lumbar cable sleeve into the adjustment cable sleeve slot.
23. Install the push pin holder to the seat bottom frame for the lumbar support cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9383
24. Install the seat bottom lower side shield into the seat bottom frame.
1 Connect the heated seat switch (if equipped).
2 Insert the lower side shield clips into the seat bottom frame.
25. Install the seat bottom lower side shield retaining screw and the lumbar support handle.
26. Connect the power seat switch electrical connector.
27. Position the seat track to the seat bottom frame. Install the four bolts (two shown) and tighten to
specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9384
28. Connect the seat motor electrical connector. 29. Install the seat into the vehicle. 30. Connect
the battery ground cable. 31. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9385
Side Air Bag: Service and Repair Side Air Bag Wiring Harness
Limited Seat
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ A side air bag repair is made by installing a new component only. If a part is replaced and the
new part does not correct the condition, install the original part and carry out the diagnostic
procedure again.
^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Disassemble the seat. For additional information refer to Seat-Front Bucket, 6-Way
Power, Except Limited, Seat-Front Bucket, Limited, or
Seat-Front Bucket, Manual.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except
Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Disassembly and Assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9386
3. Unhook the trim cover J-clip.
WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE
AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS
PERMISSIBLE).
4. Roll the seat backrest trim cover to the first row of hog rings. 5. Remove and discard the hog
rings.
6. Roll the seat backrest trim cover to the second row of hog rings.
7. Remove and discard the hog rings. 8. Roll the seat backrest trim cover to the side air bag
deployment chute.
9. Unzip the side air bag deployment chute.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9387
10. Roll the seat backrest trim cover to the third row of hog rings.
11. Remove and discard the hog rings.
12. Remove the side air bag wiring harness wire tie.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9388
13. Through the seat backrest cushion opening, position the side air bag module aside.
^ Remove the retaining nuts.
NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag
module is to be reused, then reuse the side air bag module retaining nuts.
14. Remove the side air bag module.
1 Release the side air bag module electrical connector clip.
2 Release the connector tabs by pushing in on them, then disconnect the side air bag module
electrical connector.
3 Remove the side air bag module.
15. Remove the side air bag wiring harness.
^ Disconnect the pin-type retainers from the seat backrest frame.
NOTE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9389
^ Sport bucket seat shown; Limited seat similar.
^ The seat backrest components other than the seat backrest frame and side air bag wiring
harness have been omitted for clarity.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY.
^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER
REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A
UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Install the side air bag wiring harness. Connect the pin-type retainer to the seat backrest frame.
NOTE:
^ The seat backrest components other than the seat backrest frame and side air bag wiring
harness have been omitted for clarity.
^ Sport bucket seat shown; Limited seat similar.
2. Connect the side air bag module electrical connector.
1 Install the connector to the side air bag module.
2 Slide the side air bag module electrical connector locking clip to secure the connector to the side
air bag module.
3. Make sure the electrical connector is securely fastened to the side air bag module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9390
4. Install the side air bag module onto the front seat back frame mounting bracket.
1 Position the side air bag module onto the front seat back mounting bracket being sure the side air
bag wiring harness is located behind the seat backrest frame.
2 Install the side air bag module retaining nut.
WARNING:
^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT
BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING
THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG
DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN
THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE
FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE
EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN
EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR
BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF
AN AIR BAG DEPLOYMENT.
CAUTION:
^ The retaining nuts of the side air bag module must be tightened in the sequence described.
^ Be sure the side air bag wiring harness is not pinched between the side air bag module and
mounting bracket.
5. Tie-strap the side air bag module wire harness to the seat back frame.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9391
6. Unroll the seat backrest trim cover to the third row of hog rings.
7. Install the hog rings.
8. Roll the seat back trim cover to position the deployment chute around the side air bag module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9392
9. Position the air bag deployment chute.
1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side
air bag module, pulling it around the outboard side of the seat back frame.
2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side
air bag module from the inboard side of the seat back.
WARNING:
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.
10. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and
bottom of the deployment chute, into the seat back
opening. ^
The side air bag deployment chute must encircle the side air bag module, going completely around
the side air bag module and the side of the seat back frame.
^ Align the side air bag deployment chute to the side air bag module, making sure it covers the
length of the side air bag module.
NOTE:
^ Sport bucket seat shown; Limited seat similar.
^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next
step.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9393
11. Unroll the seat backrest trim cover to the second row of hog rings.
12. Install the hog rings. 13. Unroll the seat backrest trim cover to the bottom row of hog rings. 14.
Install the hog rings.
15. Hook the trim cover clip.
NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and
off-set from the lower seat backrest trim cover J-clip.
16. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power,
Except Limited and Seat-Front Bucket, Limited.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except
Limited and Seat-Front Bucket, Limited, Disassembly and Assembly.
17. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
18. Prove out the air bag system. For additional information, refer to Air Bag Systems. 19. Check
the restraint system for proper operation.
Sport Bucket Seat
REMOVAL
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9394
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ A side air bag repair is made by installing a new component only. If a part is replaced and the
new part does not correct the condition, install the original part and carry out the diagnostic
procedure again.
^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way
Power, Except Limited, Seat-Front Bucket, Limited or
Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except
Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Manual, Disassembly and Assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9395
3. Unhook the trim cover J-clip.
WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE
AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS
PERMISSIBLE).
4. Remove the seat backrest trim cover swing rods.
1 Remove and discard the hog rings.
2 Remove the seat backrest trim cover cushion swing rods.
5. Roll the seatback trim cover in an inside out fashion to the side air bag deployment chute.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip, or
the hook and loop strip can be torn from the seat cushion foam.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9396
6. Unzip the side air bag deployment chute.
7. Roll the seat backrest cover and side air bag deployment chute to completely expose the side air
bag bracket and side air bag module.
8. Remove the side air bag wiring harness wire tie.
9. Through the seat backrest cushion opening, position the side air bag module aside.
^ Remove the retaining nuts.
NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag
module is to be reused, then reuse the side air bag module retaining nuts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9397
10. Remove the side air bag module.
1 Release the side air bag module electrical connector clip.
2 Release the connector tabs by pushing in on them, then disconnect the side air bag module
electrical connector.
3 Remove the side air bag module.
11. Remove the side air bag wiring harness.
^ Disconnect the pin-type retainers from the seat backrest frame.
NOTE:
^ Sport bucket seat shown; Limited seat similar.
^ The seat backrest components other than the seat backrest frame and side air bag wiring
harness have been omitted for clarity.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY.
^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER
REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A
UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO
FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9398
1. Install the side air bag wiring harness. Connect the pin-type retainer to the seat backrest frame.
NOTE:
^ The seat backrest components other than the seat backrest frame and side air bag wiring
harness have been omitted for clarity.
^ Sport bucket seat shown; Limited seat similar.
2. Connect the side air bag module electrical connector.
1 Install the connector to the side air bag module.
2 Slide the side air bag module electrical connector locking clip to secure the connector to the side
air bag module.
3. Make sure the electrical connector is securely fastened to the side air bag module.
4. Install the side air bag module onto the front seat back frame mounting bracket.
1 Position the side air bag module onto the front seat back mounting bracket being sure the side air
bag wiring harness is located behind the seat backrest frame.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9399
2 Install the side air bag module retaining nut.
WARNING:
^ INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT
BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING
THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG
DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN
THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE
FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE
EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN
EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR
BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF
AN AIR BAG DEPLOYMENT.
CAUTION:
^ The retaining nuts of the side air bag module must be tightened in the sequence described.
^ Be sure the side air bag wiring harness is not pinched between the side air bag module and
mounting bracket.
5. Tie-strap the side air bag module wire harness to the seat back frame.
6. Roll the seat back trim cover to position the deployment chute around the side air bag module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9400
7. Position the air bag deployment chute.
1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side
air bag module, pulling it around the outboard side of the seat back frame.
2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side
air bag module from the inboard side of the seat back.
WARNING:
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.
8. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and
bottom of the deployment chute, into the seat back
opening. ^
The side air bag deployment chute must encircle the side air bag module, going completely around
the side air bag module and the side of the seat back frame.
^ Align the side air bag deployment chute to the side air bag module, making sure it covers the
length of the side air bag module.
NOTE:
^ Sport bucket seat shown; Limited seat similar.
^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next
step.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9401
9. If equipped, install the seat backrest trim cover swing rods.
1 Position the seat backrest trim cover and install the swing rods through the sleeves.
2 Install the hog rings.
NOTE: Make sure that the top of the swing rod is positioned beneath the listing wire near the
middle row of hog rings.
10. Connect the hook and loop fastener to the seat backrest trim cover.
1 Pull the seat backrest trim cover completely down.
2 Reach up inside the seat backrest and grab the plastic above the hook and loop. Remove
enough plastic to expose the hook and loop.
11. Hook the trim cover clip.
NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and
off-set from the lower seat backrest trim cover J-clip.
12. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power,
Except Limited and Seat-Front Bucket, Limited.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except
Limited and Seat-Front Bucket, Limited, Disassembly and Assembly.
13. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
14. Prove out the air bag system. For additional information, refer to Air Bag Systems.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9402
15. Check the restraint system for proper operation.
Except Limited and Sport Bucket Seats
REMOVAL
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ DO NOT SET A LIVE SIDE AIR BAG MODULE DOWN ON THE COVER TEAR SEAM. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
^ THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
^ A side air bag repair is made by installing a new component only. If a part is replaced and the
new part does not correct the condition, install the original part and carry out the diagnostic
procedure again.
^ If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
^ Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
^ Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
^ Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
^ After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way
Power, Except Limited, Seat-Front Bucket, Limited or
Seat-Front Bucket, Manual.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except
Limited, Seat-Front Bucket, Limited, or Seat-Front Bucket, Manual, Disassembly and Assembly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9403
3. Unhook the trim cover J-clip.
WARNING: FRONT SEAT BACK TRIM COVERS INSTALLED ON SEATS EQUIPPED WITH SIDE
AIR BAGS CANNOT BE REPAIRED. THEY ARE TO BE REPLACED (CLEANING IS
PERMISSIBLE).
4. Unzip the side air bag deployment chute.
5. Remove the side air bag wiring harness wire tie.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9404
6. Through the seat backrest cushion opening, position the side air bag module aside.
^ Remove the retaining nuts.
NOTE: If installing a new side air bag module, use new retaining nuts. If the same side air bag
module is to be reused, then reuse the side air bag module retaining nuts.
7. Remove the side air bag module.
1 Release the side air bag module electrical connector clip.
2 Release the connector tabs by pushing in on them, then disconnect the side air bag module
electrical connector.
3 Remove the side air bag module.
8. Remove the side air bag wiring harness.
^ Disconnect the pin-type retainers from the seat backrest frame.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9405
NOTE: ^
Sport bucket seat shown; Limited seat similar.
^ The seat backrest components other than the seat backrest frame and side air bag wiring
harness have been omitted for clarity.
INSTALLATION
WARNING:
^ ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
^ CARRY A LIVE SIDE AIR BAG MODULE WITH THE AIR BAG AND TEAR SEAM POINTED
AWAY FROM YOUR BODY. THIS WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN
ACCIDENTAL DEPLOYMENT.
^ NEVER PROBE THE CONNECTORS ON THE AIR BAG MODULE. DOING SO CAN RESULT
IN AIR BAG DEPLOYMENT, WHICH CAN RESULT IN PERSONAL INJURY.
^ CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER, THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT. FAILURE TO DO SO MAY
RESULT IN PERSONAL INJURY.
^ THE DEPLOYMENT SEAM CANNOT BE REPAIRED OR RESEWN. A TRIM COVER
REQUIRING REPLACEMENT OF THE BOLSTER OR SIDE FACING MUST BE REPLACED AS A
UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPERLY POSITIONED AND
COMPLETELY ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY. FAILURE TO
FOLLOW THESE INSTMCTIONS MAY RESULT IN PERSONAL INJURY.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Install the side air bag wiring harness.
^ Connect the pin-type retainer to the seat backrest frame.
NOTE: ^
The seat backrest components other than the seat backrest frame and side air bag wiring harness
have been omitted for clarity.
^ Sport bucket seat shown; Limited seat similar.
2. Connect the side air bag module electrical connector.
1 Install the connector to the side air bag module.
2 Slide the side air bag module electrical connector locking clip to secure the connector to the side
air bag module.
3. Make sure the electrical connector is securely fastened to the side air bag module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9406
4. Install the side air bag module onto the front seat back frame mounting bracket.
1 Position the side air bag module onto the front seat back mounting bracket being sure the side air
bag wiring harness is located behind the seat backrest frame.
2 Install the side air bag module retaining nut.
3 Install the side air bag module retaining nut.
4 Install the side air bag module retaining nut.
WARNING: ^
INSPECT THE MOUNTING SURFACES OF THE SIDE AIR BAG MODULE AND THE SEAT
BACK FRAME MOUNTING BRACKET FOR ANY FOREIGN OBJECTS BEFORE INSTALLING
THE SIDE AIR BAG MODULE. IF ANY FOREIGN OBJECTS ARE FOUND, REMOVE THEM.
FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY, IN THE EVENT OF AN AIR BAG
DEPLOYMENT.
^ INSPECT THE SIDE AIR BAG DEPLOYMENT CHUTE AND THE SIDE AIR BAG CAVITY IN
THE SEAT BACK PAD FOR ANY FOREIGN OBJECTS. IF ANY FOREIGN OBJECTS ARE
FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE
EVENT OF AN AIR BAG DEPLOYMENT.
^ BEFORE INSTALLING THE SIDE AIR BAG MODULE, CHECK IT FOR DAMAGE AND
FOREIGN OBJECTS. IF THE AIR BAG MODULE IS DAMAGED, REPLACE IT. IF ANY FOREIGN
OBJECTS ARE FOUND, REMOVE THEM. FAILURE TO DO SO MAY RESULT IN PERSONAL
INJURY, IN THE EVENT OF AN AIR BAG DEPLOYMENT.
^ IF THE AIR BAG COVER HAS SEPARATED OR THE AIR BAG MATERIAL HAS BEEN
EXPOSED, INSTALL A NEW SIDE AIR BAG MODULE. DO NOT ATTEMPT TO REPAIR THE AIR
BAG MODULE. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY IN THE EVENT OF
AN AIR BAG DEPLOYMENT.
CAUTION: ^
The retaining nuts of the side air bag module must be tightened in the sequence described.
^ Be sure the side air bag wiring harness is not pinched between the side air bag module and
mounting bracket.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9407
5. Tie-strap the side air bag module wire harness to the seat back frame.
6. Roll the seat back trim cover to position the deployment chute around the side air bag module.
7. Position the air bag deployment chute.
1 Insert the outboard side of the air bag deployment chute between the seat back pad and the side
air bag module, pulling it around the outboard side of the seat back frame.
2 Insert the inboard side of the air bag deployment chute between the seat back pad and the side
air bag module from the inboard side of the seat back.
WARNING: ^
CHECK THE SIDE AIR BAG DEPLOYMENT CHUTE AND ZIPPER FOR DAMAGE. THE
DEPLOYMENT CHUTE AND ZIPPER MUST NOT BE REPAIRED. IF THERE IS ANY DAMAGE
TO THE DEPLOYMENT CHUTE OR ZIPPER THE SEAT BACK TRIM COVER AND
DEPLOYMENT CHUTE MUST BE INSTALLED NEW AS A UNIT.
^ IF THE AIR BAG DEPLOYMENT CHUTE IS NOT PROPELY POSITIONED AND COMPLETELY
ZIPPED, THE SIDE AIR BAG MAY NOT DEPLOY PROPERLY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Service and
Repair > Side Air Bag Module > Page 9408
8. Zip the air bag deployment chute completely closed, then position the zipper tails at the top and
bottom of the deployment chute, into the seat back
opening. ^
The side air bag deployment chute must encircle the side air bag module, going completely around
the side air bag module and the side of the seat back frame.
^ Align the side air bag deployment chute to the side air bag module, making sure it covers the
length of the side air bag module.
NOTE: ^
Sport bucket seat shown; Limited seat similar.
^ Be sure the side air bag deployment chute is properly positioned, before proceeding to the next
step.
9. Hook the trim cover clip.
NOTE: If equipped, make sure that the seat backrest heating element wire is aligned with and
off-set from the lower seat backrest trim cover J-clip.
10. Assemble the seat. For additional information, refer to Seat-Front Bucket, 6-Way Power,
Except Limited and Seat-Front Bucket, Limited.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except
Limited and Seat-Front Bucket, Limited, Disassembly and Assembly.
11. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
12. Prove out the air bag system. For additional information, refer to Air Bag Systems. 13. Check
the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Information > Locations > Page 9412
Malfunction Lamp / Indicator: Description and Operation
If an air bag system DTC or malfunction is detected, the air bag indicator is illuminated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications
Air Bag Control Module: Specifications
Restraint Control Module Bracket 12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 9417
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 9418
Air Bag Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 9419
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Specifications > Page 9420
Air Bag Control Module: Description and Operation
The Restraints Control Module (RCM) carries out the following functions:
^ signals the inflators to deploy the air bags in the event of a deployable crash.
^ monitors the air bag Supplemental Restraint System (SRS) for faults.
^ illuminates the air bag indicator if a fault is detected.
^ flashes the air bag indicator to indicate the Lamp Fault Code (LFC) detected.
^ communicates through the Data Link Connector (DLC) the current or historical Diagnostic
Trouble Codes (DTCs).
^ signals the Generic Electronic Module (GEM) to activate a chime if the air bag indicator is not
available and another SRS fault exists.
NOTE: The safety sensor is internal to the RCM and is not serviced separately.
The RCM monitors the SRS for possible faults. If a fault is detected while the ignition switch is in
the RUN position, the RCM will illuminate the air bag indicator located in the instrument cluster.
When the ignition is cycled (turned off and then on), the air bag indicator will prove out by lighting
for six seconds and then off for two seconds. After the prove out, the air bag indicator will then flash
the two-digit LFC. If an SRS fault exists, the air bag indicator will flash the LFC five times, then it
will remain illuminated for the rest of the key cycle. The RCM will also communicate the current and
historical DTCs through the DLC, to the scan tool. If the air bag indicator does not function, and the
system detects a fault condition, the RCM will signal the GEM to activate an audible chime. The
chime is a series of five sets of five tone bursts. If the chime is heard, the SRS and the air bag
indicator require repair.
LFCs are prioritized. If two or more faults occur at the same time, the fault having the highest
priority will be displayed. After that fault has been corrected, the next highest priority fault will be
displayed.
The RCM includes a backup power supply. This feature provides sufficient backup power to deploy
the air bags in the event that the ignition circuit is damaged in a collision before the safing and air
bag sensors determine that a deployment is required. The backup power supply will deplete its
stored energy approximately one minute after the battery ground cable is disconnected.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation
Air Bag Control Module: Service and Repair Removal and Installation
REMOVAL
WARNING:
^ THE RESTRAINTS CONTROL MODULE (RCM) ORIENTATION IS CRITICAL FOR PROPER
SYSTEM OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) HAS BEEN INVOLVED IN A COLLISION IN WHICH THE RIGHT
COWL A-PILLAR AREA HAS BEEN DAMAGED, INSPECT THE MOUNTING AND BRACKET
FOR DEFORMATION. IF DAMAGED, THE RCM MUST BE REPLACED WHETHER OR NOT THE
AIR BAGS HAVE DEPLOYED. IN ADDITION, MAKE SURE THE AREA OF THE RCM
MOUNTING IS RESTORED TO ITS ORIGINAL CONDITION.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the right hand cowl side trim panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation > Page 9423
3. Disconnect the Restraints Control Module (RCM).
1 Slide the two RCM electrical connector locking clips down to disengage them.
2 While squeezing the locking clip area to pivot the latch, disconnect the two RCM electrical
connectors.
4. Remove the RCM with bracket.
1 Remove the three RCM bracket retaining bolts.
2 Remove the RCM with bracket.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation > Page 9424
1. Follow the removal procedure in reverse order.
WARNING: THE TIGHTENING TORQUE OF THE RESTRAINTS CONTROL MODULE (RCM)
RETAINING BOLTS IS CRITICAL FOR PROPER SYSTEM OPERATION.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: A repair is made by installing a new part only. If the part does not correct the condition,
install the original part and perform the diagnostic procedure again.
2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation > Page 9425
Air Bag Control Module: Service and Repair Weld Nut Repair
"J" Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both procedures before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J" nuts as outlined in this procedure. Weld
nuts must be installed as outlined in Weld Nut Repair- Missing Weld Nut, Restraints Control
Module (RCM), Front External Crash and Side Crash Sensor.
^ The following procedure applies to vehicles that have a rectangular hole in the sheet metal that is
in close proximity to the missing weld nut.
1. Obtain a "J" nut (part number N623332-S301) or any of the following optional "J" nuts (part
numbers: N623342-S101, N800854-S100,
N800925-S100).
2. Obtain a 6 mm (0.24 in) grounding screw (part number N806327-S190) or equivalent. 3. Install
the "J" nut through the rectangular hole in the sheet metal. 4. Install the crash sensor.
NOTE: Be sure the threaded portion of the "J" nut is aligned with the clearance hole in the sheet
metal.
5. Tighten the attaching screws to specification.
Stripped Weld Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
1. Obtain an 8 mm (0.32 in) grounding screw (part number N802455-S190). 2. Drill out the internal
threads of the stripped-out weld nut to 7.37 mm (0.29 in) using a letter "L" size drill bit. 3. Position
the crash sensor to the vehicle. 4. Install the 8 mm (0.32 in) grounding screw into the drilled-out
weld nut. 5. Install the remaining attaching screws. 6. Tighten the attaching screws to specification.
Missing Weld Nut
WARNING:
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Service and Repair > Removal and Installation > Page 9426
LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY BATTERIES AND POWER
SUPPLIES (IF EQUIPPED).
NOTE:
^ There are two procedures to repair a vehicle having missing air bag crash sensor attaching weld
nut(s). Read both procedures before proceeding with the repair.
^ If two or more weld nuts are missing, do not install the "J", nuts as outlined in Weld Nut Repair "J"
Nut, Restraints Control Module (RCM), Front External Crash and Side Crash Sensor. Weld nuts
must be installed as outlined in this procedure.
^ Radiator support repair shown, others are similar.
1. Obtain a 6 mm (0.24 in) weld nut (part number N806285-S190). 2. Obtain a 6 mm (0.24 in)
grounding screw (part number N806327-5190).
3. Route a sufficient length of copper welding wire through the weld nut clearance hole and back
out an adjacent access hole.
4. Feed the copper welding wire through the weld nut, then through a standard flat washer. 5.
Secure the flat washer so that it cannot be pulled off the end of the copper welding wire. 6. Pull the
copper welding wire back through the clearance hole, allowing the weld nut and flat washer to
follow the copper welding wire through. 7. Position the weld nut to the weld nut clearance hole,
firmly pulling on the copper welding wire allowing the secured flat washer to hold the weld
nut in position.
8. Holding the weld nut securely in place and using a MIG welder, weld in four places around the
edge of the weld nut. 9. Metal finish as required.
10. Verify the nut is securely in place. 11. Install the crash sensor. 12. Tighten the attaching screws
to specification.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay >
Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation
Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation
Article No. 01-2-5
2/05/01
^ TRIM - SEAT BELT WARNING SYSTEM - "BELT
^ MINDER" FUNCTION - OPERATION AND SERVICE
^ TIPS
^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND
^ SERVICE TIPS
FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION,
F-150, RANGER, WINDSTAR 2001 EXPLORER
LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR
MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER
ISSUE
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning
function. This feature provides additional reminders to the driver that the driver's safety belt is
unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the
instrument cluster.
ACTION
Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by
performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt
Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following
Service Procedure.
SERVICE PROCEDURE
To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure.
1. Establish a session for the vehicle.
2. Select the "Toolbox" icon.
3. Select "Module Programming" and press the "Tick" mark.
4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark.
5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark.
6. WDS will display "Configuration Complete", then press the "Tick" mark.
NOTE:
IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT
LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH
HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT
WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS
EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE
SAFETY BELT IS BUCKLED.
NOTE:
WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND
CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT
WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND
FOR 4-8 SECONDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Warning Relay >
Component Information > Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9431
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 104000, 204000, 206000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9437
7. Remove the two steering wheel back cover plugs.
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9438
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9439
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9440
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9441
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming and Arming > Page 9442
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Prove out the system means to turn the ignition switch from the OFF to the RUN position and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately six seconds and then turn off. If an air bag Supplemental
Restraint System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Description and Operation
Child Seat Tether Attachment: Description and Operation
Attaching Safety Seats With Tether Straps
Some manufacturers make child safety seats that include a tether strap that goes over the back of
the vehicle seat and attaches to an anchoring point. Other manufacturers offer the tether strap as
an accessory. Contact the manufacturer of the child safety seat for information about ordering a
tether strap.
Attach a tether strap anchor bracket to the rear floor by using a tether anchor kit, available at no
charge from any Ford or Lincoln-Mercury dealership.
Carefully read and follow the instructions provided with the kit for installation of the child tether
strap anchor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Specifications
Seat Belt: Specifications
Rear Seat Center Occupant Safety Belt And Retractor Bolt 40 Nm
Safety Belt Anchor Bolts 40 Nm
Safety Belt Guide To Floor Bolt 40 Nm
Safety Belt Guide To Seat Track Bolt 9.0 Nm
Safety Belt Guide To Seat Track Nut 9.0 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Safety Belt Cleaning
Seat Belt: Service and Repair Safety Belt Cleaning
1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning
upholstery or carpets. Follow the instructions provided
with the soap.
WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS THE WEBBING MAY WEAKEN.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Safety Belt Cleaning > Page 9452
Seat Belt: Service and Repair Safety Belt With Anchor Plate Thread Damage
1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt
anchor plate with a 10.7 mm (27/64 in) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat
belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with
the repair parts indicated in the Safety Belt Parts Replacement Guidelines. See:
Parts Replacement Chart
6. When repairing a multiple belt and attachment, install the nut to the bolt in the tunnel area from
the underside of the floorpan.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Safety Belt Cleaning > Page 9453
Seat Belt: Service and Repair Replacement Of The Weld Nut And Reinforcement
1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut
only or the weld nut and reinforcement and weld nut are missing. If the B or C- or D- pillar safety
belt anchor nuts or
reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement.
To install a missing weld nut only, proceed to Step 3.
3. Obtain a M12 weld nut and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes
adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through
clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire
through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld
nut clearance bole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder
106-00053 to plug weld the nut in place at the two 8 mm (5/16 in)diameter
holes previously drilled.
9. Metal finish as required.
10. Verify the nut is securely in place.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Safety Belt Cleaning > Page 9454
Seat Belt: Service and Repair Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts
D-Ring Installation Kit
SPECIAL SERVICE TOOLS
1. Remove the B-pillar trim panel.
2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the
damaged threads in the upper pillar structure.
3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation
Kit and tap new threads.
NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any
chips before proceeding.
4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into
the retapped hole until it is slightly below the
surface.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Safety Belt Cleaning > Page 9455
5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several
times to seat the insert keys.
NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Safety Belt Cleaning > Page 9456
Seat Belt: Service and Repair
Safety Belt Cleaning
1. Clean the safety belt webbing only with a mild soap solution recommended for cleaning
upholstery or carpets. Follow the instructions provided
with the soap.
WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS THE WEBBING MAY WEAKEN.
Safety Belt With Anchor Plate Thread Damage
1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt
anchor plate with a 10.7 mm (27/64 in) drill. 3. Rethread the anchor plate with a 1/2-13 tap (seat
belt). 4. Clean out the chips. 5. Install the attachment parts. Original parts are to be replaced with
the repair parts indicated in the Safety Belt Parts Replacement Guidelines. See:
Parts Replacement Chart
6. When repairing a multiple belt and attachment, install the nut to the bolt in the tunnel area from
the underside of the floorpan.
Replacement Of The Weld Nut And Reinforcement
1. Remove the interior trim panel to expose the suspect anchor point. 2. Determine if the weld nut
only or the weld nut and reinforcement and weld nut are missing. If the B or C- or D- pillar safety
belt anchor nuts or
reinforcements are stripped or missing, they should be replaced with a new nut or reinforcement.
To install a missing weld nut only, proceed to Step 3.
3. Obtain a M12 weld nut and a standard washer. 4. Drill out two 8 mm (5/16 in) diameter holes
adjacent to the clearance hole. 5. Obtain a length of copper welding wire and feed through
clearance hole in door frame opening until it becomes visible at the access hole. 6. Pull the wire
through so that it may be secured to the weld nut and washer. 7. Pull the wire back up to the weld
nut clearance bole. 8. Hold the weld nut securely in place. Use the MIG Wire Feed Welder
106-00053 to plug weld the nut in place at the two 8 mm (5/16 in)diameter
holes previously drilled.
9. Metal finish as required.
10. Verify the nut is securely in place.
Safety Belt Shoulder Height Adjuster With Stripped Weld Nuts
D-Ring Installation Kit
SPECIAL SERVICE TOOLS
1. Remove the B-pillar trim panel.
2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the
damaged threads in the upper pillar structure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Safety Belt Cleaning > Page 9457
3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation
Kit and tap new threads.
NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any
chips before proceeding.
4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into
the retapped hole until it is slightly below the
surface.
5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several
times to seat the insert keys.
NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster.
Safety Belt Tongue Rotated on Belt
1. Fold the safety belt as indicated.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and
Repair > Safety Belt Cleaning > Page 9458
2. Pull the safety belt tongue over the fold in the safety belt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Specifications
Seat Belt Buckle: Specifications
Driver Seat Safety Belt Buckle Nut 40 Nm
Front Seat Safety Belt Buckle Bolt 40 Nm
Rear Seat Safety Belt Buckle Assembly Rear Nuts 48 Nm
Rear Seat Safety Belt Buckle Front Nuts 40 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Specifications > Page 9462
Seat Belt Buckle: Locations
Buckles, Four-Door
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Specifications > Page 9463
Buckles, Two-Door
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information >
Specifications > Page 9464
Seat Belt Buckle: Description and Operation
When replacing safety belt buckle or retractor assemblies, use only the replacement parts specified
in the Ford Customer Service Division Master Parts Catalog.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Bucket Seats
Seat Belt Buckle: Service and Repair Bucket Seats
Safety Belt Bolt Bit
SPECIAL SERVICE TOOLS
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Remove the floor console.
2. Move the seat forward and use Safety Belt Bolt Bit to remove the slide bar bolt. 3. Remove the
front seat.
4. Remove the safety belt slide bar.
1 Disconnect the electrical connector (LH only).
2 Remove the nut.
3 Remove the bolt.
4 Remove the slide bar.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Bucket Seats > Page 9467
5. Remove the safety belt buckle.
1 Clamp the slide bar in a suitable vise.
2 Use Safety Belt Bolt Bit to remove the bolt.
3 Remove the buckle.
NOTE: Clamp the slide bar collar in a vise along the break line only.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Bucket Seats > Page 9468
Seat Belt Buckle: Service and Repair Rear Seat
Four-Door
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Remove the rear seats.
2. Remove the rear safety belt buckle assembly.
1 Remove the nuts.
2 Remove the rear safety belt buckle assembly.
INSTALLATION
1. To install, reverse the removal procedure.
^ Check the restraint system for proper operation.
Two-Door
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Remove the rear seats.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service
and Repair > Bucket Seats > Page 9469
2. Remove the rear safety belt buckles.
1 Remove the nuts.
2 Remove the rear safety belt buckles.
INSTALLATION
1. To install, reverse the removal procedure.
^ Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information >
Description and Operation
Seat Belt Extension: Description and Operation
In certain cases, the safety belt may be too short even when it is fully extended. About 20 cm (8 in)
can be added to the belt length by using a safety belt extension. Safety belt extensions are
available at no cost from any Ford or Lincoln-Mercury dealer parts department. Safety belt
extensions are only available with black webbing.
There are two extension assemblies available, one for the front seating positions and one for the
rear seating positions and they are not interchangeable.
Use only extensions manufactured by the same supplier as the safety belt. Manufacturer
identification is located at the end of the webbing on the label. Also, use the safety belt extension
only if safety belt is too short for you when fully extended. Do not use extension to change the fit of
the shoulder belt across the torso.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Specifications
Seat Belt Height Adjuster: Specifications
Shoulder Safety Belt Height Adjuster Bolts 40 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Removal and Installation
Seat Belt Height Adjuster: Service and Repair Removal and Installation
Four-Door
Safety Belt Bolt Bit
SPECIAL SERVICE TOOLS
REMOVAL
1. Remove the B-pillar trim panel.
2. Remove the height adjuster cover.
3. Remove the shoulder safety belt height adjuster.
1 Use Safety Belt Bolt Bit to remove the two bolts.
2 Remove the shoulder safety belt height adjuster.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Removal and Installation > Page 9478
1. Use Safety Belt Bolt Bit and install the shoulder safety belt height adjuster.
2. Install the height adjuster cover. 3. Install the B-pillar trim panel. 4. Check the restraint system for
proper operation.
Two-Door
Safety Belt Bolt Bit
SPECIAL SERVICE TOOLS
REMOVAL
1. Remove the quarter trim panel.
2. Remove the height adjuster cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Removal and Installation > Page 9479
3. Remove the shoulder safety belt height adjuster.
1 Use Safety Belt Bolt Bit to remove the two bolts.
2 Remove the shoulder safety belt height adjuster.
INSTALLATION
1. Use Safety Belt Bolt Bit and install the shoulder safety belt height adjuster.
2. Install the height adjuster cover. 3. Install the quarter trim panel. 4. Check the restraint system
for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Removal and Installation > Page 9480
Seat Belt Height Adjuster: Service and Repair General Procedures
D-Ring Installation Kit
SPECIAL SERVICE TOOLS
1. Remove the B-pillar trim panel.
2. Use the half-inch drill with integral stop provided in D-Ring Installation Kit to drill out the
damaged threads in the upper pillar structure.
3. Apply a suitable lubricant to the M14 x 1.5 tap with integral stop provided in D-Ring Installation
Kit and tap new threads.
NOTE: After each rotation, back off tap slightly to remove new cuttings and be sure to blow out any
chips before proceeding.
4. Use a threaded insert (N807170-S190) provided in the D-Ring Installation Kit and screw it into
the retapped hole until it is slightly below the
surface.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Height Adjuster > Component Information >
Service and Repair > Removal and Installation > Page 9481
5. Use a hammer to lightly tap the installation tool provided in the D-Ring Installation Kit several
times to seat the insert keys.
NOTE: If the two bolts on the height adjuster are not stripped, install the height adjuster.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Locations > Page 9485
Seat Belt Reminder Lamp: Description and Operation
The safety belt warning indicator is powered through the GEM/CTM module. When the ignition key
is turned on, the indicator illuminates for four to eight seconds even if the safety belt is buckled.
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information >
Locations > Page 9486
Seat Belt Reminder Lamp: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts
Slow to Retract
Seat Belt Retractor: Customer Interest Restraints - Seat Belts Slow to Retract
TSB 05-16-11
08/22/05
SAFETY BELT RETRACTION SPEED
FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport,
Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty,
Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape
Hybrid 2004-2006 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator
MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006
Monterey 2005-2006 Mariner
This article supersedes TSB 04-24-21 to update the vehicle model years.
ISSUE A service kit is now available to improve safety belt retraction speed.
ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet
included in the kit. Refer to Workshop Manual Section 501-20A for additional information.
NOTE
TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES
LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE
MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE
THREE VEHICLES.
NOTE
FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE
FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE
HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES.
^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on
vehicles built on/after 6/16/2003.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles
built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles
built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Customer Interest for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints - Seat Belts
Slow to Retract > Page 9495
Parts Block
NOTE
THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS
NEEDED TO COVER THE REQUIRED REPAIRS.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051611A Install Teflon Tape B 0.8 Hr.
Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary)
051611B Install Teflon Tape C 1.1 Hrs.
Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary)
DEALER CODING
CONDITION
BASIC PART NO. CODE
70611B08 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract
Seat Belt Retractor: All Technical Service Bulletins Restraints - Seat Belts Slow to Retract
TSB 05-16-11
08/22/05
SAFETY BELT RETRACTION SPEED
FORD: 2000-2003 Mustang 2000-2006 Crown Victoria, Taurus 2000-2003 Explorer Sport,
Windstar 2000-2005 Excursion, Explorer 2000-2006 E-Series, Expedition, F-150, F-Super Duty,
Ranger 2001-2005 Explorer Sport Trac 2001-2006 Escape 2004-2006 Freestar 2005-2006 Escape
Hybrid 2004-2006 F-650, F-750
LINCOLN: 2000-2002 Continental 2000-2006 LS, Town Car, Navigator 2003-2005 Aviator
MERCURY: 2000-2005 Sable 2000-2006 Grand Marquis 2000-2005 Mountaineer 2004-2006
Monterey 2005-2006 Mariner
This article supersedes TSB 04-24-21 to update the vehicle model years.
ISSUE A service kit is now available to improve safety belt retraction speed.
ACTION See the part application chart and select the appropriate kit. Follow the Instruction Sheet
included in the kit. Refer to Workshop Manual Section 501-20A for additional information.
NOTE
TEFLON TAPE SHOULD ONLY BE USED ON THE FRONT ROW SEATS FOR VEHICLES
LISTED IN THIS TSB, WITH THE EXCEPTION OF THE AVIATOR, EXPLORER 4DR AND THE
MOUNTAINEER. TEFLON TAPE CAN ALSO BE USED ON SECOND ROW SEATS FOR THESE
THREE VEHICLES.
NOTE
FOR MUSTANG, AVIATOR, EXPLORER 4DR AND MOUNTAINEER, REFER TO THE
FOLLOWING BUILD DATE INFORMATION BEFORE PERFORMING THIS TSB. TEFLON TAPE
HAS ALREADY BEEN INSTALLED DURING PRODUCTION ON SOME OF THESE VEHICLES.
^ MUSTANG: Only install on vehicles built through 6/15/2003. Teflon tape was already installed on
vehicles built on/after 6/16/2003.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (FRONT ROW SEATS): Only install on vehicles
built through 6/24/2004. Teflon tape was already installed on vehicles built on/after 6/25/2004.
^ AVIATOR, EXPLORER 4DR/MOUNTAINEER (SECOND ROW SEATS): Only install on vehicles
built through 10/21/2004. Teflon tape was already installed on vehicles built on/after 10/22/2004.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Retractor: > 05-16-11 > Aug > 05 > Restraints Seat Belts Slow to Retract > Page 9501
Parts Block
NOTE
THE LABOR OPERATIONS WITHIN THIS TSB CAN BE CLAIMED IN COMBINATION AS
NEEDED TO COVER THE REQUIRED REPAIRS.
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
051611A Install Teflon Tape B 0.8 Hr.
Pillars Both Sides (Includes Time To Remove And Install Trim Panels If Necessary)
051611B Install Teflon Tape C 1.1 Hrs.
Pillars Both Sides (Includes Time To Remove And Install Trim Panels And Seats If Necessary)
DEALER CODING
CONDITION
BASIC PART NO. CODE
70611B08 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 9502
Seat Belt Retractor: Specifications
Rear Seat Center Occupant Safety Belt And Retractor Bolt 40 Nm
Safety Belt Retractor Bolts 40 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 9503
Seat Belt Retractor: Description and Operation
The shoulder harness retractor is designed to let the webbing move freely in or out at all times,
except during vehicle hard braking, hard cornering or an impact of 8 km/h (5 mph) or more, when it
is automatically locked by a mechanically actuated inertia sensor.
DUAL LOCKING MODE RETRACTORS
NOTE: When replacing a dual locking mode retractor, the retractor should be checked to make
sure it is not in the Automatic Locking Retractor (ALR) mode after installation in the stowed
position.
All outboard continuous-loop, three-point retractor systems, except the driver position, are
equipped with the dual locking mode system.
The Emergency Locking Retractor (ELR) mode will allow the occupant freedom of movement,
locking tight only on hard braking, hard cornering, or an impact of approximately 8 km/h (5 mph).
The ELR mode helps to reduce the forward movement of the driver and passengers. The ELR
mode is continuously in operation at all seating positions.
The ALR portion of this system does not allow the occupant freedom of movement. The ALR mode
is used when locking a child seat in an outboard seating position or when a tight belt fit is desired.
The ALR mode is disengaged when the webbing is free to move in or out of the retractor. The ALR
mode is automatically engaged when the webbing is fully extracted from the retractor and then
allowed to retract. As the webbing is retracted back onto the spool, an audible clicking sound is
made, indicating that the retractor is in ALR mode. The ALR mode is automatically disengaged
when most of the webbing is retracted back onto the spool.
WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL
OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC
LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO
VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS
STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY
BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF
THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE OR ANY
OTHER SAFETY BELT FUNCTION IS NOT OPERATING PROPERLY WHEN CHECKED
ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE
THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN
COLLISIONS.
This vehicle has a safety belt system with an energy management feature at the front seating
positions to help further reduce the risk of injury in the event of a head-on collision.
This safety belt system has a retractor assembly that is designed to pay out webbing in a controlled
manner. This feature is designed to help reduce the belt force acting on occupant's chest.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Technical Service Bulletins > Page 9504
Seat Belt Retractor: Testing and Inspection
WARNING: AFTER ANY VEHICLE COLLISION, THE SAFETY BELT SYSTEM AT ALL
OUTBOARD SEATING POSITIONS (EXCEPT DRIVER, WHICH HAS NO "AUTOMATIC
LOCKING RETRACTOR" FEATURE) MUST BE CHECKED BY A QUALIFIED TECHNICIAN TO
VERIFY THAT THE "AUTOMATIC LOCKING RETRACTOR" FEATURE FOR CHILD SEATS IS
STILL FUNCTIONING PROPERLY, IN ADDITION TO OTHER CHECKS FOR PROPER SAFETY
BELT SYSTEM FUNCTION. A BELT AND RETRACTOR ASSEMBLY MUST BE REPLACED IF
THE SAFETY BELT ASSEMBLY'S "AUTOMATIC LOCKING RETRACTOR" FEATURE, OR ANY
OTHER SAFETY BELT FUNCTION, IS NOT OPERATING PROPERLY WHEN CHECKED
ACCORDING TO THE PROCEDURES IN THE WORKSHOP MANUAL. FAILURE TO REPLACE
THE BELT AND RETRACTOR ASSEMBLY COULD INCREASE THE RISK OF INJURY IN
COLLISIONS.
1. Extend the safety belt to latch the tongue into the buckle across an empty seat without slack in
the safety belt, with the seat in the full down and
rearmost position, seat back in an upright position, and if applicable, the D-ring adjusted in the full
down position.
2. Pull the shoulder belt to full extension to engage the retractor's Automatic Locking Retractor
(ALR) feature. Then allow the belt to retract freely in
the ALR mode, and the retractor force set the proper belt tightness.
3. Pull on the shoulder belt to check that the belt has remained in the ALR mode. If the belt is not
locked, install a new belt and retractor assembly.
The safety belt should remain locked in the ALR mode across an empty seat.
4. To verify that the safety belt still automatically disengages from the ALR mode properly, with the
D-ring adjusted to the full up position, if
applicable, unlatch the safety belt tongue from the buckle and allow the safety belt to retract to its
stowed position. Pull on the shoulder belt to verify that the retractor assembly has converted
automatically out of the ALR mode. If the belt remains locked in the stowed position, a new belt and
retractor assembly must be installed. The safety belt should extract freely.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > B-Pillar Retractor
Seat Belt Retractor: Service and Repair B-Pillar Retractor
Two-Door
Safety Belt Bolt Bit
SPECIAL SERVICE TOOLS
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Remove the quarter trim panel.
2. Remove the front safety belt retractor.
1 Use Safety Belt Bolt Bit to remove the bolt.
2 Remove the front safety belt retractor.
INSTALLATION
1. Use Safety Belt Bolt Bit to install the front safety belt retractor. 2. Install the quarter trim panel. 3.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > B-Pillar Retractor > Page 9507
Driver Side and Outside Passenger,Four-Door
Safety Belt Bolt Bit
SPECIAL SERVICE TOOLS
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Remove the B-pillar trim panel.
2. Remove the front safety belt retractor.
1 Use Safety Belt Bolt Bit to remove the bolts.
2 Remove the front safety belt retractor.
INSTALLATION
1. Use Safety Belt Bolt Bit to install the front safety belt retractor. 2. Install the B-pillar trim panel. 3.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > B-Pillar Retractor > Page 9508
Seat Belt Retractor: Service and Repair C-Pillar Retractor
Four-Door
Safety Belt Bolt Bit
SPECIAL SERVICE TOOLS
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Remove the quarter trim panel.
2. Remove the safety belt retractor.
1 Use Safety Belt Bolt Bit to remove the bolt.
2 Remove the safety belt retractor.
INSTALLATION
1. Use Safety Belt Bolt Bit to install the safety belt retractor. 2. Install the quarter trim panel. 3.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > B-Pillar Retractor > Page 9509
Two-Door
Safety Belt Bolt Bit
SPECIAL SERVICE TOOLS
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Remove the quarter trim panel.
2. Remove the safety belt retractor.
1 Use Safety Belt Bolt Bit to remove the bolts.
2 Remove the safety belt retractor.
INSTALLATION
1. Use Safety Belt Bolt Bit to install the safety belt retractor. 2. Install the quarter trim panel. 3.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information >
Service and Repair > B-Pillar Retractor > Page 9510
Seat Belt Retractor: Service and Repair Rear Seat Retractor and Buckle Assembly, Four-Door
Safety Belt Bolt Bit
SPECIAL SERVICE TOOLS
REMOVAL
WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, BUCKLES, FRONT
SEAT BELT BUCKLE SUPPORT ASSEMBLIES (SLIDE BAR), SHOULDER BELT HEIGHT
ADJUSTERS (IF SO EQUIPPED) CHILD SAFETY SEAT TETHER ATTACHMENTS AND
ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT
ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE
ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. BELT ASSEMBLIES NOT IN
USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER
DAMAGE OR IMPROPER OPERATION IS NOTED.
1. Fold the rear seat down to load floor position.
2. Remove the rear safety belt buckle and retractor assembly.
1 Use Safety Belt Bolt Bit to remove the bolt.
2 Remove the rear safety belt buckle and retractor assembly.
INSTALLATION
1. To install, reverse the removal procedure.
^ Check the restraint system for proper operation.
NOTE: Make sure the safety belt webbing is not twisted prior to installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information >
Technical Service Bulletins > Seat Belts - Warning System Operation
Seat Belt Warning Relay: Technical Service Bulletins Seat Belts - Warning System Operation
Article No. 01-2-5
2/05/01
^ TRIM - SEAT BELT WARNING SYSTEM - "BELT
^ MINDER" FUNCTION - OPERATION AND SERVICE
^ TIPS
^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND
^ SERVICE TIPS
FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION,
F-150, RANGER, WINDSTAR 2001 EXPLORER
LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR
MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER
ISSUE
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning
function. This feature provides additional reminders to the driver that the driver's safety belt is
unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the
instrument cluster.
ACTION
Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by
performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt
Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following
Service Procedure.
SERVICE PROCEDURE
To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure.
1. Establish a session for the vehicle.
2. Select the "Toolbox" icon.
3. Select "Module Programming" and press the "Tick" mark.
4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark.
5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark.
6. WDS will display "Configuration Complete", then press the "Tick" mark.
NOTE:
IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT
LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH
HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT
WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS
EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE
SAFETY BELT IS BUCKLED.
NOTE:
WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND
CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT
WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND
FOR 4-8 SECONDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Relay > Component Information >
Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9515
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 104000, 204000, 206000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information >
Technical Service Bulletins > Seat Belts - Warning System Operation
Seat Belt Warning Timer: Technical Service Bulletins Seat Belts - Warning System Operation
Article No. 01-2-5
2/05/01
^ TRIM - SEAT BELT WARNING SYSTEM - "BELT
^ MINDER" FUNCTION - OPERATION AND SERVICE
^ TIPS
^ ELECTRICAL - SEAT BELT WARNING SYSTEM ^ "BELT MINDER" FUNCTION - OPERATION AND
^ SERVICE TIPS
FORD: 2000-2001 CROWN VICTORIA, MUSTANG, TAURUS, EXCURSION, EXPEDITION,
F-150, RANGER, WINDSTAR 2001 EXPLORER
LINCOLN: 2000-2001 CONTINENTAL, TOWN CAR 2001 LS 2000-2001 NAVIGATOR
MERCURY: 2000-2001 GRAND MARQUIS, SABLE 2001 MOUNTAINEER
ISSUE
The above vehicles have a "Belt Minder" feature that is supplemental to the safety belt warning
function. This feature provides additional reminders to the driver that the driver's safety belt is
unbuckled by intermittently sounding a chime and illuminating the safety belt warning light on the
instrument cluster.
ACTION
Some customers may wish to have the Belt Minder deactivated or reactivated. This can be done by
performing the deactivation procedure in the Owner Guide (section on Safety Restraints, Belt
Minder) or by using the Worldwide Diagnostic System (WDS) tool and performing the following
Service Procedure.
SERVICE PROCEDURE
To deactivate or reactivate the Belt Minder using the WDS tool, refer to the following procedure.
1. Establish a session for the vehicle.
2. Select the "Toolbox" icon.
3. Select "Module Programming" and press the "Tick" mark.
4. Select "Programmable Parameters", then "Warning Lamps/Chimes" and press the "Tick" mark.
5. Select "Beltminder - (HEC)", then select "Enabled or Disabled" and press the "Tick" mark.
6. WDS will display "Configuration Complete", then press the "Tick" mark.
NOTE:
IF THE DRIVER'S SAFETY BELT IS NOT BUCKLED BEFORE THE VEHICLE HAS REACHED AT
LEAST 5 KM/H (3 MPH) AND 1-2 MINUTES HAVE ELAPSED SINCE THE IGNITION SWITCH
HAS BEEN TURNED ON, THEN THE BELT MINDER WILL ILLUMINATE THE SAFETY BELT
WARNING LIGHT AND WILL SOUND THE SAFETY BELT WARNING CHIME FOR 6 SECONDS
EVERY 30 SECONDS, REPEATING FOR APPROXIMATELY 5 MINUTES OR UNTIL THE
SAFETY BELT IS BUCKLED.
NOTE:
WHEN THE BELT MINDER IS DEACTIVATED, THE SAFETY BELT WARNING LIGHT AND
CHIME WILL CONTINUE TO OPERATE NORMALLY. THE SAFETY BELT WARNING LIGHT
WILL REMAIN ILLUMINATED FOR 1-2 MINUTES AND THE WARNING CHIME WILL SOUND
FOR 4-8 SECONDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information >
Technical Service Bulletins > Seat Belts - Warning System Operation > Page 9520
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 104000, 204000, 206000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Specifications
Impact Sensor: Specifications
Side Crash Sensor 12 Nm
Front Crash Sensor 10.2-13.8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Driver Side Air Bag Crash Sensor
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Driver Side Air Bag Crash Sensor > Page 9527
Impact Sensor: Locations Front Crash Sensors
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Driver Side Air Bag Crash Sensor > Page 9528
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Driver Side Air Bag Crash Sensor > Page 9529
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Locations > Driver Side Air Bag Crash Sensor > Page 9530
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front External Crash Sensor
Impact Sensor: Service and Repair Front External Crash Sensor
REMOVAL
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Disconnect the battery ground cable and wait at least one minute. 2. Remove the radiator grill
and radiator opening cover.
3. Remove the air bag sensor.
1 Disconnect the air bag sensor electrical connector.
2 Remove the three screws.
3 Remove the air bag sensor.
INSTALLATION
WARNING: VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM
OPERATION. IF A VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT
SYSTEM (SRS) IS INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET
AND WIRING PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE
SENSOR OR ANY OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
COMPONENTS WHETHER OR NOT THE AIR BAG IS DEPLOYED.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: A repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front External Crash Sensor > Page 9533
1. Follow the removal procedure in reverse order. 2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front External Crash Sensor > Page 9534
Impact Sensor: Service and Repair Side Crash Sensor
REMOVAL
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ TO AVOID ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY, THE BACKUP
POWER SUPPLY MUST BE DEPLETED BEFORE REPAIRING OR REPLACING ANY FRONT
OR SIDE AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS AND
BEFORE SERVICING, REPLACING, ADJUSTING OR STRIKING COMPONENTS NEAR THE
FRONT OR SIDE AIR BAG SENSORS, SUCH AS DOORS, INSTRUMENT PANEL, CONSOLE,
DOOR LATCHES, STRIKERS, SEATS AND HOOD LATCHES.
^ PLEASE REFER TO THE APPROPRIATE COMPONENT OR SYSTEM TO DETERMINE
LOCATION OF THE FRONT AIR BAG SENSORS.
^ THE SIDE AIR BAG SENSORS ARE LOCATED AT OR NEAR THE BASE OF THE B-PILLAR.
^ TO DEPLETE THE BACKUP POWER SUPPLY ENERGY, DISCONNECT THE BATTERY
GROUND CABLE AND WAIT AT LEAST ONE MINUTE. BE SURE TO DISCONNECT AUXILIARY
BATTERIES AND POWER SUPPLIES (IF EQUIPPED).
NOTE:
^ Repair is made by installing a new part only. If the new part does not correct the condition, install
the original part and perform the diagnostic procedure again.
^ Right side is shown, left side is similar.
1. Disconnect the battery ground cable and wait at least one minute.
2. Remove the B-pillar lower trim panel with scuff plates.
NOTE: ^
Four door is shown, two door is similar.
^ The front seat has been removed for clarity.
3. Remove the side crash sensor.
1 Disconnect the side crash sensor electrical connector.
2 Remove the two retaining bolts.
3 Remove the side crash sensor with bracket.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component
Information > Service and Repair > Front External Crash Sensor > Page 9535
WARNING:
^ VEHICLE SENSOR ORIENTATION IS CRITICAL FOR PROPER SYSTEM OPERATION. IF A
VEHICLE EQUIPPED WITH AN AIR BAG SUPPLEMENTAL RESTRAINT SYSTEM (SRS) IS
INVOLVED IN A COLLISION, INSPECT THE SENSOR MOUNTING BRACKET AND WIRING
PIGTAIL FOR DEFORMATION. REPLACE AND PROPERLY POSITION THE SENSOR OR ANY
OTHER DAMAGED SUPPLEMENTAL RESTRAINT SYSTEM (SRS) COMPONENTS WHETHER
OR NOT THE AIR BAG IS DEPLOYED.
^ THE TIGHTENING TORQUE OF THE AIR BAG SIDE CRASH SENSOR RETAINING BOLTS IS
CRITICAL FOR PROPER SYSTEM OPERATION.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage can result.
NOTE: Repair is made by installing a new part only. If the new part does not correct the condition,
install the original part and perform the diagnostic procedure again.
1. Follow the removal procedure in reverse order. 2. Prove out the air bag system.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE
COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations
Accessory Delay Relay: Locations
The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay
Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Accessory Delay Relay >
Component Information > Locations > Page 9541
Accessory Delay Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component
Information > Locations > Page 9546
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information >
Service and Repair
Antenna Motor: Service and Repair
REMOVAL
NOTE: The antenna motor and the antenna cable is removed as an assembly.
1. Disconnect the battery ground cable.
2. Unsnap the radio antenna base cap.
3. Remove the radio antenna nut.
4. Remove the front fender apron.
1 Remove the screws.
2 Remove the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information >
Service and Repair > Page 9553
5. Remove lower antenna mounting screw. 6. Remove the RH cowl side trim panel.
7. Disconnect the antenna motor electrical connector. 8. Remove the audio unit. For additional
information, refer to Radio, Stereo, and Compact Disc.
9. Position the antenna lead in cable into the engine compartment.
1 Open the glove compartment door.
2 Release the tabs and lower the glove compartment to the full open position.
3 Release the antenna lead in cable wire locators.
4 Push the antenna lead in cable into the engine compartment.
10. Move the electric antenna motor forward and down to remove. 11. If necessary, to remove a
broken section of plastic antenna drive cable, remove the cover and drive mechanism. 12. Locate
and remove the broken piece of drive cable.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information >
Service and Repair > Page 9554
NOTE: The antenna motor and antenna cable are installed as an assembly.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Fixed Antenna Cable
Antenna Cable: Service and Repair Fixed Antenna Cable
REMOVAL
NOTE: The antenna base and the antenna cable are removed as an assembly.
1. Disconnect the battery ground cable.
2. Remove the radio antenna mast.
^ Slide the wind deflector up.
^ Remove the radio antenna mast by turning it counterclockwise.
3. Unsnap the radio antenna base cap.
4. Remove the radio antenna nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Fixed Antenna Cable > Page 9560
5. Remove the front fender apron.
1 Remove the screws.
2 Remove the bolts.
6. Remove the lower antenna mounting screw. 7. Remove the RH cowl side trim panel. 8. Remove
the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc.
9. Position the antenna lead-in cable into the engine compartment.
1 Open the glove compartment door.
2 Release the tabs and lower the glove compartment to the full open position.
3 Release the antenna lead-in cable locators.
4 Push the antenna lead-in cable into the engine compartment.
10. Remove the antenna base and the antenna lead-in cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Fixed Antenna Cable > Page 9561
INSTALLATION
NOTE: The antenna base and the antenna cable are installed as an assembly.
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Fixed Antenna Cable > Page 9562
Antenna Cable: Service and Repair Power Antenna Cable
REMOVAL
NOTE: The power antenna cable and the antenna mast are removed as an assembly.
1. Unsnap the radio antenna base cap.
2. Remove the radio antenna nut. 3. Remove the antenna mast and cable.
^ Turn the ignition switch to the ACC position.
^ Turn the radio chassis ON/OFF switch to ON.
^ Firmly pull the antenna mast and cable out of the electric antenna motor.
INSTALLATION
NOTE: The power antenna cable and antenna mast are installed as an assembly.
1. Position the cable so the teeth are facing the front of the vehicle.
NOTE: Check the end of the plastic antenna drive cable for a slight taper. If the drive cable is
broken, a section of cable may be inside the electric antenna motor. Remove the broken cable.
Refer to Antenna-Motor.
2. Insert the antenna.
^ Manually extend the antenna.
^ Insert the cable until resistance is felt.
^ Turn the cable slightly left and right to full engage the cable into the motor gear.
3. Have an assistant turn the ignition switch to ACC and turn the radio chassis ON/OFF switch from
ON to OFF. 4. Apply light downward pressure to the antenna as the electric antenna motor starts
retracting the cable. 5. Guide the antenna in as the motor winds the cable into the drive unit and
retracts the antenna sections.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable >
Component Information > Service and Repair > Fixed Antenna Cable > Page 9563
6. Install the radio antenna nut. 7. Install the radio antenna base cap. 8. Cycle the electric antenna
motor several times to ensure the antenna is extending and retracting correctly.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Locations
Alarm Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Locations > Page 9568
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Locations > Page 9569
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9572
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9573
Alarm Module: Diagrams Remote Anti-Theft Personality Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module > Page 9574
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Page 9575
Alarm Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Page 9576
Alarm Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle
Antitheft) > Component Information > Diagrams > Page 9577
Alarm Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Service Precautions
Alarm System Transponder: Service Precautions
CAUTION: Once the new module is installed, it is necessary to configure the module. For
additional information, refer to Module Communication Network (Information Bus).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS)
Alarm System Transponder: Service and Repair Module-Passive Anti-Theft System (PATS)
REMOVAL
1. Remove the passenger side air bag module; refer to Air Bags.
2. Remove the passive anti-theft system (PATS) module and bracket.
1 Remove the bolts.
2 Disconnect the electrical connector.
3. Release the retainer tabs and remove the PATS module from the bracket.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 9583
1. To install, reverse the removal procedure.
CAUTION: Once the new module is installed, it is necessary to configure the module. For
additional information, refer to Module Communication Network (Information Bus).
NOTE: ^
Prior to starting the vehicle, check for PATS DTCs. Perform the appropriate pinpoint test.
^ When the PATS module is replaced, both ignition keys must be relearned and stored in memory.
Insert each key in the ignition and turn to RUN for automatic programming.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 9584
Alarm System Transponder: Service and Repair Module-Passive Anti-Theft Transceiver
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these charges,
damage may result.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to the RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. Twist the tilt wheel handle and shank and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 9585
5. Remove the hood latch release handle.
1 Remove the screws.
2 Remove the hood latch release handle.
6. Remove the lower instrument panel steering column cover.
1 Remove the screws.
2 Remove the lower instrument panel steering column cover.
7. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the screws.
2 Remove the instrument panel steering column opening cover reinforcement.
8. Remove the transceiver assembly.
1 Remove the screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm System
Transponder > Component Information > Service and Repair > Module-Passive Anti-Theft System (PATS) > Page 9586
2 Locate the rib on the steering column lock cylinder housing, and gently release the anti-theft
transceiver over the rib.
NOTE: Only apply pressure or leverage below the key cylinder lower rib.
3 Disconnect the electrical connector.
NOTE: The steering wheel is shown removed for clarity.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 ml) or
more to relearn the strategy.
^ No key replacement or re-initialization needs to occur with the removal or installation of a new
PATS Transceiver.
^ The steering wheel is shown removed for clarity.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch,
Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder
Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder
REMOVAL
1. Remove the driver door trim panel.
3. Remove the door disarm switch.
1 Remove the "E" clip.
2 Remove the lock rod actuator.
3 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The door disarm switch locator mark must be positioned towards the harness side of the
switch prior to installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Arm/Disarm Switch,
Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 9591
Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder
REMOVAL
1. Remove the liftgate trim panel. 2. Remove the watershield.
3. Remove the liftgate lock cylinder disarm switch.
1 Remove the "E" clip.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side
of the switch prior to installation.
^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal,
Antitheft > Component Information > Service and Repair
Ignition Key In Signal: Service and Repair
Key-In-Ignition Warning Switch
REMOVAL
1. Remove the ignition switch lock cylinder.
1 Insert the ignition key and turn to the RUN position.
2 Insert a punch in the access hole of the steering column and press the release tab while pulling
out the ignition switch lock cylinder.
2. Remove the key-in-ignition warning switch.
1 Pry the clip down.
2 Push the key-in-ignition warning switch off the rear of the ignition switch lock cylinder.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Ignition Key In Signal,
Antitheft > Component Information > Service and Repair > Page 9595
1. To install, reverse the removal procedure.
^ Verify ignition switch lock cylinder operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics
Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics
TSB 06-15-8
08/07/06
KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY
FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005
Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006
Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006
F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005
Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar
LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator
2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT
MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan
1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner
ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to
properly diagnose the concern with the keyless entry keypad, it is important to identify whether the
keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF)
style keypad.
ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic
service tips.
SERVICE PROCEDURE
IDENTIFICATION:
1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and
are wired directly to the module controlling the vehicle's keyless entry system. This style keypad
can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9601
2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13
mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM
(Figure 1).
NOTE
THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES
BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD
DIAGNOSTICS FOR THESE VEHICLES.
GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS
1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed
using a similar procedure.
Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter
programming portion of the WSM, Section 501-14 can be used as a guide
NOTE
THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY
DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN
ADDITIONAL REMOTE TRANSMITTER.
Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic
pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the
lock / unlock functions will differ
2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced
separately.
3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be
replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super
Duty vehicles produced prior to 12/3/2003).
4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by
vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is
replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM
etc.) is replaced.
NOTE
THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED
KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR
VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN
THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME
ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING
PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD
SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL
CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE.
5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the
illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all
doors). The keypad contains an optical sensor and will not illuminate under bright lighting
conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the
battery power available to transmit a lock/unlock signal. The temperature at which this occurs will
vary depending upon the keypad battery age and condition. Both of these conditions are a normal
function of the Power Save Mode and do not indicate a need to replace the keypad.
6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it
again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication
that battery power is very low and the keypad must be replaced.
7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35
consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash
during this time.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 9602
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A626 42
Disclaimer
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Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9603
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9604
Keyless Entry Key-Pad: Service Precautions
CAUTION: Do not operate the radio chassis with a radio speaker disconnected.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9605
Keyless Entry Key-Pad: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the front door trim panel.
CAUTION: Do not operate the radio chassis with a radio speaker disconnected.
3. Remove the screws and lift the radio speaker out to gain access to the electrical connector.
4. Disconnect the speaker wiring connector.
5. Disconnect the electrical connector.
- Release harness pin-type retainers.
6. Remove the keyless entry keypad and harness.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Key-Pad > Component Information > Technical Service Bulletins > Page 9606
1 Remove the clip.
2 Remove the keyless entry keypad and harness.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km)
or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9612
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9613
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9614
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9615
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9616
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9617
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9618
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9619
Keyless Entry Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9620
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9621
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9622
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9623
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9624
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9625
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Page 9626
Keyless Entry Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Page 9627
Keyless Entry Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless
Entry Module > Component Information > Diagrams > Page 9628
Keyless Entry Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch >
Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder
Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder
REMOVAL
1. Remove the driver door trim panel.
3. Remove the door disarm switch.
1 Remove the "E" clip.
2 Remove the lock rod actuator.
3 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The door disarm switch locator mark must be positioned towards the harness side of the
switch prior to installation.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch >
Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock Cylinder > Page 9633
Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder
REMOVAL
1. Remove the liftgate trim panel. 2. Remove the watershield.
3. Remove the liftgate lock cylinder disarm switch.
1 Remove the "E" clip.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side
of the switch prior to installation.
^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch.
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator >
Component Information > Locations
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Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Security Lamp/Indicator >
Component Information > Locations > Page 9637
Security Lamp/Indicator: Description and Operation
Once triggered, the anti-theft system flashes the low beam headlamps, the parking lamps, the
THEFT indicator and sounds the horns.
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Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations
Parking Assist Control Module: Locations
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Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 9642
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Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 9643
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Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Control Module > Component Information > Locations > Page 9644
Parking Assist Control Module: Service and Repair
REMOVAL
1. Remove the jack storage panel.
2. Remove the parking aid module.
1 Disconnect the electrical connector.
2 Remove the screws.
3 Remove the parking aid module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking
Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings
Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings
TSB 05-4-18
03/07/05
FALSE PARKING AID WARNINGS
FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty
LINCOLN: 2000-2001 Navigator
MERCURY: 1999-2001 Mountaineer
This article supersedes TSB 04-26-2 to update the vehicle lines and model years.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE TIPS
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive.
The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters)
from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
BLOCKED/CONTAMINATED PROXIMITY SENSOR
SURFACE:
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Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking
Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9653
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water wash to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid
module parameter identification displays (PIDs) for distance information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest for Parking
Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9654
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select the appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT:
^ Toolbox Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False
Warnings
TSB 05-4-18
03/07/05
FALSE PARKING AID WARNINGS
FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty
LINCOLN: 2000-2001 Navigator
MERCURY: 1999-2001 Mountaineer
This article supersedes TSB 04-26-2 to update the vehicle lines and model years.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE TIPS
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive.
The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters)
from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
BLOCKED/CONTAMINATED PROXIMITY SENSOR
SURFACE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9660
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water wash to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid
module parameter identification displays (PIDs) for distance information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9661
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select the appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT:
^ Toolbox Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9662
Parking Assist Distance Sensor: Specifications
Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm
Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor
160 cm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9663
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9664
Parking Assist Distance Sensor: Service and Repair
REMOVAL
1. Remove the rear bumper.
2. Remove the parking aid sensor.
1 Disconnect the electrical connector.
2 Release the tabs.
3 Remove the parking aid sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Switch > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Switch > Component Information > Diagrams > Page 9668
Parking Assist Switch: Service and Repair
REMOVAL
1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc.
2. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel.
^ Disconnect the electrical connector.
3. Remove the hood latch release handle.
1 Remove the screws.
2 Remove the hood latch release handle.
4. Remove the instrument panel lower steering column cover.
1 Remove the screws.
2 Remove the instrument panel lower steering column cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Switch > Component Information > Diagrams > Page 9669
5. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the screws.
2 Remove the instrument panel steering column opening cover reinforcement.
6. If equipped, position the column gearshift lever aside.
7. Remove the instrument cluster finish panel.
1 Remove the screws.
2 Remove the instrument cluster finish panel. ^
Disconnect the electrical connector.
8. Remove the parking aid switch.
1 Remove the screws.
2 Remove the parking aid switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Collision Avoidance and Parking Assist Systems >
Parking Assist Warning Indicator > Component Information > Service and Repair
Parking Assist Warning Indicator: Service and Repair
REMOVAL
1. Remove the LH quarter trim panel.
2. Remove the parking aid speaker.
1 Disconnect the electrical connector.
2 Remove the pin-type retainers.
3 Remove the parking aid speaker.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions
Driver/Vehicle Information Display: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Information > Diagrams > Diagram Information and Instructions > Page 9677
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Information > Diagrams > Diagram Information and Instructions > Page 9679
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 9680
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Information > Diagrams > Diagram Information and Instructions > Page 9681
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 9682
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 9683
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Information > Diagrams > Diagram Information and Instructions > Page 9684
Driver/Vehicle Information Display: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 9685
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Information > Diagrams > Diagram Information and Instructions > Page 9688
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Information > Diagrams > Diagram Information and Instructions > Page 9689
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 9690
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 9691
Driver/Vehicle Information Display: Connector Views
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Information > Diagrams > Diagram Information and Instructions > Page 9692
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Information > Diagrams > Diagram Information and Instructions > Page 9693
Driver/Vehicle Information Display: Electrical Diagrams
Diagram 69-1
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Diagram 69-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Description and Operation > System Description
Driver/Vehicle Information Display: Description and Operation System Description
The message center system consists of:
- message center switch module
- message center indicator
Message Center Switch Module The message center switch module has seven switches and is
located below the message center indicator in the center console. The message center switches
are: ENGLISH/METRIC mode
- fuel computer (FUEL) RANGE
- STATUS
- economy (ECON)
- RESET
- system check and warnings (SYSTEM CHECK)
- OIL CHANGE RESET
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Information > Description and Operation > System Description > Page 9697
Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It
Work ?)
Display Dimming
The dimming of the indicator display is controlled by the pulse width dimmer module. The voltage
on Pin 2 controls the brightness of the message center display. When the exterior lamps are off,
this voltage will be zero volts and the message center display will be at maximum brightness. When
the exterior lamps are on, this voltage will be controlled by the pulse width dimmer module and will
be between 2.5 volts and battery voltage. The message center display will be brighter as this
voltage approaches battery voltage. If there is a warning on the message center display, the
display will not dim to its lowest level.
When the headlamps or parking lamps are OFF, the display of the message center indicator will be
maximum brightness and the labels for the center five switches of the message center switch
module will not be illuminated.
When the head lamps or parking lamps are ON, the brightness of the display of the message
center indicator and the labels for the center five switches of the message center switch module will
be controlled by the pulse width dimmer module.
English/Metric Mode
The ENGLISH/METRIC switch controls the display mode for both the message center indicator and
the electronic automatic temperature control. A press of the ENGLISH/METRIC switch will change
both displays between english mode and metric mode.
Vehicle Speed Signal
The vehicle speed signal is generated by the rear anti-lock brake sensor and sent to the 4-wheel
Anti-lock Brake System (4WABS) module. The 4WABS module sends the vehicle speed signal via
circuit 679 (GY/BK) to all systems which require a vehicle speed signal input.
Fuel Computer - Range
The RANGE feature has two displays: the distance that can be traveled before refueling, and the
distance that was traveled since the last trip odometer reset. The RANGE switch will change the
message center indicator between the two displays.
The RANGE (distance to empty) feature is calculated using the fuel flow signal from the Powertrain
Control Module (PCM), the speed signal from the 4WABS module and the fuel level signal from the
fuel level sender.
The fuel flow and speed signals are used to calculate a Running Average Fuel Economy (RAFE),
which is multiplied by the fuel remaining to give the range.
RAFE is not the same number as the Average Fuel Economy displayed by the message center
indicator.
RAFE is based on the past driving history and can only be reset by disconnecting the battery.
When the range decreases to 80 km (50 mile) to empty, the message center will display the LOW
FUEL LEVEL warning.
With a fuel tank full of fuel (160 ohm signal from fuel sender) and after a battery disconnect, the
RANGE should be approximately 644 km (400 miles) to empty.
The RANGE (trip odometer) feature is calculated using the speed signal from the 4WABS module.
It can be reset to zero by pressing the reset switch while the trip odometer is displayed on the
message center.
Fuel Computer - Status
The STATUS feature has two displays: Fuel-to-Empty and Fuel-Used. The STATUS switch will
change the message center indicator between the two displays.
The fuel-to-empty calculation is achieved using the fuel level signal from the fuel level sender.
The fuel-used feature is calculated using the fuel flow signal from the PCM and can be reset to
zero by pressing the RESET switch while the fuel-used feature is displayed on the message center.
Fuel Computer - Economy
The Economy (ECON) feature has two displays: average and instant.
Depressing the ECON switch changes the message center indicator between both displays.
The economy is calculated using the fuel flow signal from the powertrain control module and the
speed signal from the 4WABS module.
The average fuel economy feature can be reset by pressing the RESET switch while the average
fuel economy feature is displayed on the message center indicator.
System Check and Warnings
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Description and Operation > System Description > Page 9698
The SYSTEM CHECK feature cycles the message center indicator through a status of each system
being monitored. For each of the monitored systems, the message center indicator will indicate either an OK
message or a warning message for two seconds.
- At normal conclusion of the system check sequence, the message center indicator will display all
active warnings or the last feature displayed before entering the SYSTEM CHECK mode.
- System warnings alert the driver to possible concerns or malfunctions in the vehicle operating
systems.
- There are 7 warning messages which can be displayed for two seconds by the message center
indicator to show the status of the monitored systems.
- When a warning occurs, the warning message is displayed and a one-second tone sounds. The
warning message will appear at a brighter level if the message center indicator is dimmed.
- In the event of a multiple warning situation, the message center indicator will cycle the display to
show all warnings by displaying each warning message for four seconds.
- To display the operator selectable features of the message center indicator while a warning is
displayed, the warning message may be removed from the message center indicator display by
pressing the RESET switch. The message center indicator will display the last selected feature if
there are no more warning messages.
- This allows operation of all functions of the message center indicator after pressing the RESET
switch and clearing the warning message.
Warning messages which have been reset will either reappear on the display in 10 minutes from
the reset or will not reappear until an ignition switch OFF-RUN cycle.
If warning messages reappear it is a reminder that these warning conditions still exist. Warnings
may be repeatedly reset. All warning messages will reappear after an entire SYSTEM CHECK
sequence has been completed.
Charging System Warning (CHECK CHARGING SYSTEM)
This warning message is displayed when the electrical system is not maintaining correct voltage at
the message center indicator. There will be a few seconds delay before the warning is displayed or
removed.
Engine Coolant Temperature Warning (CHECK ENGINE TEMP)
This warning message is displayed when the engine coolant is overheating.
The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message
center indicator).
If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be
no warning. If it is less than approximately 2.7 volts, at a battery voltage of 13.5 volts then the
warning will be displayed.
The message center indicator filters this input; therefore, there will be a few seconds delay before
the warning is displayed or removed.
Fuel Level Warning (LOW FUEL LEVEL)
This warning message is displayed when there is approximately 80 km (50 mile) or less left before
the vehicle runs out of fuel.
Oil Level Warning (LOW OIL LEVEL)
This warning message is displayed when the engine oil level is low.
When the engine oil level is normal, the input to the message center indicator will be an open
circuit.
When the engine oil level is low, the low oil level sensor will close, grounding the input to the
message center indicator and the warning will be displayed during the next ignition cycle of OFF to
RUN. This low oil level sensor is only monitored when the ignition switch is OFF.
There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the
oil pan and reach the correct level.
Oil Life Warning (CHANGE OIL SOON or OIL CHANGE REQUIRED)
If the connection to the oil temperature sensor is open circuit or shorted, the message center
display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE
LEFT during system cheek sequence.
One of these warning messages is displayed when the engine oil life remaining is five percent or
less. When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will
be displayed.
- When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be
displayed.
The message center indicator will indicate the percent of oil life remaining during System Check.
This percentage is based on the driving history and the time since the last oil change. In order to
ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET
procedure, as described in the Owner's Guide, after an oil change.
To calculate the percentage of oil life remaining, the oil life feature uses: oil temperature sensor input
- tachometer input from the PCM
- vehicle speed signal input
- clock time (maintained internally by the message center)
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Description and Operation > System Description > Page 9699
- The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or
6 months. It will reach zero percent sooner under different driving conditions.
- The percentage of oil life remaining is the second display in the system check sequence.
- When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON"
message will be displayed.
- When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be
displayed.
Washer Fluid Level Warning (LOW WASHER FLUID)
This warning message is displayed when there is less than one quarter of the container of washer
fluid remaining When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will close,
grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator.
- When the washer fluid level is low, the input to the message center indicator will be open and the
warning will be displayed.
The message center indicator filters this input therefore, there will be a 20-second delay before the
warning is displayed or removed.
Warning Chime
A short warning chime (0.1 second) is output with every message center switch press. A longer
warning chime (1.0 second) is output when a new warning first appears on the message center
indicator display.
To activate the warning, the message center pulls the chime request output below one volt during
the length of the tone.
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Description and Operation > Page 9700
Driver/Vehicle Information Display: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Message Center Assembly
Driver/Vehicle Information Display: Service and Repair Message Center Assembly
REMOVAL
1. Remove the message center console. Grasp the front of the console and lift upward.
2. Disconnect the electrical connectors from the message center indicator.
3. Remove the screws retaining the message center indicator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Message Center Assembly > Page 9703
Driver/Vehicle Information Display: Service and Repair Message Center Assembly Switch
REMOVAL
1. Remove the message center indicator. Refer to Driver/Vehicle Information Display.
2. Disconnect the electrical connector.
3. Remove the message center switch module screws and remove the module.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Page 9704
73 Digital Multimeter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations > Page 9708
Garage Door Opener Transmitter: Service Precautions
WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE
ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL
SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT
USE THIS HOMELINK(R) WITH TRAVELNOTE TM TRANSMITTER WITH A DOOR OPENING
SYSTEM THAT LACKS STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL
STANDARDS. THIS INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED
BEFORE APRIL 1, 1982. FOR MORE INFORMATION, CALL HOMELINK(R) WITH TRAVELNOTE
TM CUSTOMER ASSISTANCE AT 1-800-355-3515.
CAUTION: During this procedure, the system that you are programming will be made to operate.
Make sure that people or objects are clear of the garage door or gate being programmed.
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Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Locations > Page 9709
Garage Door Opener Transmitter: Description and Operation
The HomeLink(R) with TravelNote TM universal transmitter provides a convenient way to replace
up to three hand-held transmitters with a single built-in device. The universal transmitter:
^ will operate garage doors, gates and home/office lighting and security systems.
^ will actually learn and transmit the radio frequency of up to three hand-held transmitters from any
of the systems mentioned above.
^ is an integral part of the left sun visor assembly and is powered by the vehicle battery and
charging system.
In addition to the universal transmitter function, the HomeLink(R) with TravelNote TM also provides
a convenient built-in recording device to safely store information.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of
mechanical damage.
VISUAL INSPECTION CHART
Mechanical ^
Damaged universal transmitter
^ Damaged receiver
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
before proceeding to the next step. 4. If the fault is not visually evident, verify the symptom and
refer to the Symptom Chart. See: Symptom Related Diagnostic Procedures
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Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9712
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Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9713
Garage Door Opener Transmitter: Pinpoint Tests
Connector Circuit Reference
Refer to the Vehicle/Diagrams for schematic and connector information.
A1 - A2
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Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Page 9714
Garage Door Opener Transmitter: Service and Repair
WARNING: A GARAGE DOOR OPENING SYSTEM THAT CANNOT STOP OR REVERSE
ITSELF AFTER DETECTING AN OBJECT IN ITS PATH DOES NOT MEET CURRENT FEDERAL
SAFETY STANDARDS. TO DECREASE THE RISK OF SERIOUS INJURY OR DEATH, DO NOT
USE THIS HOMELINK(R) WITH TRAVELNOTE TM TRANSMITTER WITH A DOOR OPENING
SYSTEM THAT LACKS STOP AND REVERSE FEATURES AS REQUIRED BY FEDERAL
STANDARDS. THIS INCLUDES ANY GARAGE DOOR OPENING SYSTEM MANUFACTURED
BEFORE APRIL 1, 1982. FOR MORE INFORMATION, CALL HOMELINK(R) WITH TRAVELNOTE
TM CUSTOMER ASSISTANCE AT 1-800-355-3515.
1. Verify the hand-held transmitter is operative.
CAUTION: During this procedure, the system that you are programming will be made to operate.
Make sure that people or objects are clear of the garage door or gate being programmed.
2. Prepare for programming the universal transmitter by erasing all three channels by holding down
the two outside buttons until the red light begins
to flash (20 - 30 seconds). Release both buttons.
3. Select one of the three universal transmitter channels to be programmed by pressing the desired
button. 4. Hold the end of the hand-held transmitter 25 - 51 mm (1 - 2 in) from the front surface of
the universal transmitter so that the red light can still be
seen.
5. Use both hands to press the hand-held transmitter button and the desired button on the
universal transmitter. Do not release either button.
NOTE: During programming, the hand-held transmitter may automatically stop transmitting after
two seconds, which may not be long enough to program the universal transmitter. If programming
this type of hand-held transmitter, continue to hold the button on the universal transmitter while
re-pressing the hand-held transmitter button every two seconds (Canada only).
6. Hold down both buttons until the red light on the universal transmitter flashes, first slowly and
then rapidly. Release both buttons when the rapid
flashing begins. The universal transmitter has successfully learned the new frequency signal and
can be used in place of the hand-held transmitter(s).
7. To operate, simply press the appropriate button on the universal transmitter. The red light is on
while the signal is being transmitted.
NOTE: If the hand-held transmitter appears to program the universal transmitter but does not open
the garage door, the garage door opener may have a "code protected" or "rolling code" feature.
Training a Garage Door Opener Equipped With "Rolling Codes" 1. Program the hand-held
transmitter to the universal transmitter. 2. Train the garage door opener receiver to recognize the
universal transmitter.
1 Remove the cover panel from the garage door opener receiver.
2 Locate the training button on the garage door opener receiver. Location and color of the button
may vary by garage door opener manufacturer. Refer to the garage door opener instruction manual
or call HomeLink(R) with TravelNote TM customer assistance at 1-800-355-3515.
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Ford Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component
Information > Testing and Inspection > Page 9715
3 Press the training button on the garage door opener receiver for 1 - 2 seconds.
4 Press the programmed universal transmitter button for as long as the universal transmitter red
light flashes (1 - 2 seconds). Release the button and re-press the button to confirm that the
universal transmitter is trained to the receiver.
5 The garage door opener should recognize the universal transmitter.
Erasing Channels 1. To erase all three programmed channels, hold down the two outside buttons
until the red light begins to flash (20 - 30 seconds). Release both
buttons.
NOTE: Individual channels cannot be erased, but can be reprogrammed using the procedures for
programming.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Specifications
Multifunction Electronic Control Modules: Specifications
Remote Anti-Theft Personality Module 2.3-3.3 Nm
Battery Ground Cable Screws 7-10 Nm
GEM/CTM Screw 1.6-2.0 Nm
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Specifications > Page 9719
Multifunction Electronic Control Modules: Locations
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Specifications > Page 9720
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions
Multifunction Electronic Control Modules: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9723
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9724
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9725
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9726
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9727
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9728
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9729
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9730
Multifunction Electronic Control Modules: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9731
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9732
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9734
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9735
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9736
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9737
Multifunction Electronic Control Modules: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9738
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9739
Multifunction Electronic Control Modules: Electrical Diagrams
Diagram 59-1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9740
Diagram 59-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9741
Diagram 59-3
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9742
Diagram 59-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9743
Diagram 59-5
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 9744
Diagram 59-6
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Page 9745
Multifunction Electronic Control Modules: Description and Operation
The multifunction modules consist of the following:
^ generic electronic module (GEM)/central timer module (CTM)
^ remote anti-theft personality (RAP) module
The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated
locks systems.
The GEM/CTM controls the following features:
^ wiper/washer (front/rear)
^ warning chime
^ battery saver
^ illuminated entry and courtesy lamps
^ driver one touch down power window (GEM only)
^ accessory delay
^ 4 wheel drive (GEM only)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Diagrams > Page 9746
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM)
Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic
(GEM)/Central Timer (CTM)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1 Remove the screw.
2 Disconnect the four connectors from the GEM/CTM.
3 Remove the GEM/CTM.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page
9749
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page
9750
Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft
Personality (RAP)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static
charges, damage may result.
2. Remove the LH rear quarter trim panel.
3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors.
4. Remove the two RAP module fasteners.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Multifunction Electronic Control Modules <--> [General
Module] > Component Information > Service and Repair > Module - Generic Electronic (GEM)/Central Timer (CTM) > Page
9751
5. Remove the RAP module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Navigation System > Navigation Module > Component
Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Specifications
Amplifier: Specifications
Radio Amplifier Bracket Bolt 10-14 Nm
Radio Amplifier Bracket Nut 7-9 Nm
Radio Amplifier Bracket Screw 7-10 Nm
Radio Amplifier Mounting Screw 7-10 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound
System > Component Information > Specifications > Page 9764
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player
(CD) > CD Changer > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player
(CD) > CD Changer > Component Information > Diagrams > Page 9769
CD Changer: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the console compartment trim panel.
^ Remove the screws.
^ Remove the console compartment trim panel.
3. Remove the coin holder/tissue box holder.
4. Position the CD changer aside.
1 Remove the screws.
2 Position aside the CD changer.
5. Remove the CD changer.
1 Disconnect the connector.
2 Remove the screws.
3 Remove the CD changer brackets.
4 Remove the CD changer.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player
(CD) > CD Changer > Component Information > Diagrams > Page 9770
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9780
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9781
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9782
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9783
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9784
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9785
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9786
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio
Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9792
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9793
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9794
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9795
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9796
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9797
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 01-7-3 > Apr > 01 > Fuel Pump - Whine Heard Through Radio Speakers > Page 9798
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 9799
Radio/Stereo Noise Filter: Specifications
Intake Manifold Ground Strap Nut
...................................................................................................................................................... 7-9
Nm (62-80 Lb-In) Radio Chassis Rear Support Nut
.......................................................................................................................................................
3.5-4 Nm (31-35 Lb-In) Rear Integrated Control Panel Screws
.................................................................................................................................................. 2-3
Nm (17-26 Lb-In) Wiper Motor Stud Ground Strap Nut
................................................................................................................................................... 7-9
Nm (62-80 Lb-In) Rear Radio Chassis Support
..............................................................................................................................................................
3.5-4 Nm (31-35 Lb-In) Battery Ground Cable Screw
..............................................................................................................................................................
7-10 Nm (62-89 Lb-In) Cylinder Head Ground Strap Bolt
.............................................................................................................................................. 8.9-12.1
Nm (79-107 Lb-In)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 9800
Radio/Stereo Noise Filter: Description and Operation
Radio Frequency Interference Suppression Equipment
The radio suppression equipment reduces interference transmitted through the radio speakers by
the engine ignition and electrical systems.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 9801
Radio/Stereo Noise Filter: Service and Repair
GROUND STRAP
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the nut and washer (A) attaching the ground strap (B) to the stud.
3. Remove the fastener from the rear of the right cylinder head and ensure that the mounting
surfaces of the studs are free of dirt and corrosion.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 9802
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Service and Repair
Remote Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the steering wheel controls.
1 Carefully remove the steering wheel controls.
2 Disconnect the steering wheel controls.
NOTE: The steering wheel is leather wrapped and should be protected when removing the steering
wheel controls.
INSTALLATION
1. Install the steering wheel controls.
1 Connect the steering wheel controls.
2 Install the steering wheel controls.
2. Connect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Service and Repair
Remote Control: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the console compartment trim panel screws.
3. Remove the console compartment door hinge screw.
4. Remove the console rear panel screws at the top of the panel.
5. Remove the console rear panel screws at the cupholder.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Service and Repair > Page 9809
6. Remove the rear integrated control panel screws.
7. Disconnect the floor/panel control arm at the control head.
8. Disconnect the rear blower motor control and rear radio controls electrical connectors.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Remote Control,
Audio - Stereo > Component Information > Service and Repair > Page 9810
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers
Speaker: Customer Interest Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9819
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9820
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9821
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9822
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9823
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9824
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 01-7-3 > Apr > 01 > Fuel Pump Whine Heard Through Radio Speakers > Page 9825
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers
Speaker: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9831
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9832
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9833
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9834
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9835
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9836
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 9837
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Page 9838
Speaker: Specifications
Speaker Screws 2 Nm
Subwoofer Screws 6.8-9.2 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Page 9839
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Technical Service Bulletins > Page 9840
Speaker: Description and Operation
The Explorer and Mountaineer are equipped with four premium radio speakers and an optional
subwoofer. Rear radio speakers are mounted in the rear doors in four-door models or in the quarter
panel in two-door models. Front radio speakers are mounted in the front doors. The optional MACH
sound system replaces the front door premium radio speakers with audiophile radio speakers.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Mounted Speakers
Speaker: Service and Repair Door Mounted Speakers
REMOVAL
1. Remove the front door trim panels.
2. Remove the speakers.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the speakers.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Mounted Speakers > Page 9843
Speaker: Service and Repair Rear (2 Door) Speaker
REMOVAL
1. Remove the quarter trim panel.
2. Remove the speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > Door Mounted Speakers > Page 9844
Speaker: Service and Repair Subwoofer Speaker
REMOVAL
1. Remove the quarter trim panel.
2. Remove the subwoofer.
1 Disconnect the electrical connector.
2 Remove the screws.
3 Remove the subwoofer.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations
Accessory Delay Relay: Locations
The Generic Electronic Module (GEM) / Central Timer Module (CTM) Controls the Accessory Delay
Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Accessory Delay Module > Accessory Delay Relay > Component Information > Locations > Page 9850
Accessory Delay Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations
Alarm Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9854
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations > Page 9855
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module >
Page 9858
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module >
Page 9859
Alarm Module: Diagrams Remote Anti-Theft Personality Module
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Anti-Theft Transceiver Module >
Page 9860
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9861
Alarm Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9862
Alarm Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Diagrams > Page 9863
Alarm Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Antenna Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Antenna Control Module > Component Information > Locations > Page 9867
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications
Multifunction Electronic Control Modules: Specifications
Remote Anti-Theft Personality Module 2.3-3.3 Nm
Battery Ground Cable Screws 7-10 Nm
GEM/CTM Screw 1.6-2.0 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications >
Page 9871
Multifunction Electronic Control Modules: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Specifications >
Page 9872
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions
Multifunction Electronic Control Modules: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9875
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9876
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9877
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9878
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9879
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9880
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9881
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9882
Multifunction Electronic Control Modules: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9883
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9884
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9885
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9886
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9887
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9888
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9889
Multifunction Electronic Control Modules: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9890
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9891
Multifunction Electronic Control Modules: Electrical Diagrams
Diagram 59-1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9892
Diagram 59-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9893
Diagram 59-3
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9894
Diagram 59-4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9895
Diagram 59-5
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams >
Diagram Information and Instructions > Page 9896
Diagram 59-6
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page
9897
Multifunction Electronic Control Modules: Description and Operation
The multifunction modules consist of the following:
^ generic electronic module (GEM)/central timer module (CTM)
^ remote anti-theft personality (RAP) module
The remote anti-theft personality (RAP) module controls the keyless entry, and computer operated
locks systems.
The GEM/CTM controls the following features:
^ wiper/washer (front/rear)
^ warning chime
^ battery saver
^ illuminated entry and courtesy lamps
^ driver one touch down power window (GEM only)
^ accessory delay
^ 4 wheel drive (GEM only)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Diagrams > Page
9898
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair
> Module - Generic Electronic (GEM)/Central Timer (CTM)
Multifunction Electronic Control Modules: Service and Repair Module - Generic Electronic
(GEM)/Central Timer (CTM)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
2. Remove the radio chassis; refer to Radio, Stereo, and Compact Disc.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
4. Remove the GEM/CTM.
1 Remove the screw.
2 Disconnect the four connectors from the GEM/CTM.
3 Remove the GEM/CTM.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair
> Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9901
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair
> Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9902
Multifunction Electronic Control Modules: Service and Repair Module - Remote Anti-Theft
Personality (RAP)
REMOVAL
1. Disconnect the battery ground cable.
CAUTION: Electronic modules are sensitive to electrical charges. If exposed to these static
charges, damage may result.
2. Remove the LH rear quarter trim panel.
3. Disconnect the two remote anti-theft personality (RAP) module electrical connectors.
4. Remove the two RAP module fasteners.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Multifunction Electronic Control Modules <--> [General Module] > Component Information > Service and Repair
> Module - Generic Electronic (GEM)/Central Timer (CTM) > Page 9903
5. Remove the RAP module.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9909
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9910
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9911
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9912
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9913
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9914
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9915
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9916
Keyless Entry Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9917
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9918
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9919
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9920
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9921
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Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Diagram Information and Instructions > Page
9922
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9923
Keyless Entry Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9924
Keyless Entry Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Diagrams > Page 9925
Keyless Entry Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Navigation Module > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations
Parking Assist Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 9932
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 9933
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Parking Assist Control Module > Component Information > Locations > Page 9934
Parking Assist Control Module: Service and Repair
REMOVAL
1. Remove the jack storage panel.
2. Remove the parking aid module.
1 Disconnect the electrical connector.
2 Remove the screws.
3 Remove the parking aid module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front
Door Lock Cylinder
Arm/Disarm Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder
REMOVAL
1. Remove the driver door trim panel.
3. Remove the door disarm switch.
1 Remove the "E" clip.
2 Remove the lock rod actuator.
3 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The door disarm switch locator mark must be positioned towards the harness side of the
switch prior to installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Arm/Disarm Switch, Antitheft > Component Information > Service and Repair > Switch -Door Disarm, Front
Door Lock Cylinder > Page 9940
Arm/Disarm Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder
REMOVAL
1. Remove the liftgate trim panel. 2. Remove the watershield.
3. Remove the liftgate lock cylinder disarm switch.
1 Remove the "E" clip.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side
of the switch prior to installation.
^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock
Cylinder
Lock Cylinder Switch: Service and Repair Switch -Door Disarm, Front Door Lock Cylinder
REMOVAL
1. Remove the driver door trim panel.
3. Remove the door disarm switch.
1 Remove the "E" clip.
2 Remove the lock rod actuator.
3 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The door disarm switch locator mark must be positioned towards the harness side of the
switch prior to installation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Switch -Door Disarm, Front Door Lock
Cylinder > Page 9945
Lock Cylinder Switch: Service and Repair Switch-Door Disarm, Liftgate Lock Cylinder
REMOVAL
1. Remove the liftgate trim panel. 2. Remove the watershield.
3. Remove the liftgate lock cylinder disarm switch.
1 Remove the "E" clip.
2 Disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: ^
The liftgate lock cylinder disarm switch locator mark must be positioned towards the harness side
of the switch prior to installation.
^ Depress the liftgate lock cylinder to install the liftgate lock cylinder disarm switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest
for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings
Parking Assist Distance Sensor: Customer Interest Parking Assist System - False Warnings
TSB 05-4-18
03/07/05
FALSE PARKING AID WARNINGS
FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty
LINCOLN: 2000-2001 Navigator
MERCURY: 1999-2001 Mountaineer
This article supersedes TSB 04-26-2 to update the vehicle lines and model years.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE TIPS
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive.
The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters)
from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
BLOCKED/CONTAMINATED PROXIMITY SENSOR
SURFACE:
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest
for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9954
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water wash to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid
module parameter identification displays (PIDs) for distance information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Customer Interest
for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings > Page 9955
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select the appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT:
^ Toolbox Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings
Parking Assist Distance Sensor: All Technical Service Bulletins Parking Assist System - False
Warnings
TSB 05-4-18
03/07/05
FALSE PARKING AID WARNINGS
FORD: 1999-2001 Explorer, Windstar 2000-2001 Excursion, Expedition 2001 F-Super Duty
LINCOLN: 2000-2001 Navigator
MERCURY: 1999-2001 Mountaineer
This article supersedes TSB 04-26-2 to update the vehicle lines and model years.
ISSUE Vehicles equipped with the parking aid reverse sensing system (RSS) may sound a warning
tone when the vehicle is in reverse, even though there are no objects behind the vehicle. This
condition may also occur on vehicles equipped with the forward sensing system (FSS) when
vehicle is in reverse or drive.
ACTION The condition MAY NOT be due to proximity sensor(s) malfunction but may be a normal
operation characteristic, or due to sensor contamination (sensor being covered with dirt). Refer to
the following description of OPERATION AND COMMON CAUSE OF WARNINGS, before
replacing any sensor(s).
SERVICE TIPS
NOTE
THE FOLLOWING DESCRIPTIONS ARE TRUE FOR BOTH THE RSS AND FSS.
OPERATION AND COMMON CAUSE OF WARNINGS
The RSS is only operational when the vehicle is in reverse. For vehicles also equipped with the
FSS the system is operational when the vehicle is in reverse or drive.
The FSS and RSS give an audible warning to the driver when obstacles are within 6' (1.8 meters)
from the vehicle, and when obstacles are within 18" (46 cm) on either side of the bumper.
NOTE
CERTAIN OBSTACLES MAY BE DIFFICULT FOR THE RSS/FSS TO DETECT DEPENDING ON
GEOMETRIC SHAPE OR PROFILE OF THE OBJECT AND THE MATERIAL THE OBJECT IS
COMPOSED OF.
NOTE
THE NEAREST OBSTACLE WILL ALWAYS BE THE OBSTACLE REPORTED, WITH THE
EXCEPTION STATED IN THE NOTE ABOVE.
NOTE
THE VEHICLE OPERATOR MUST BE AWARE THAT THE WARNING TONES ARE AT A
MODERATE VOLUME LEVEL AND THAT THE TONES MAY BE DIFFICULT TO HEAR WITH
BACKGROUND NOISE (RADIO, BLOWERS, PASSENGER CONVERSATION, ETC). THE
RSS/FSS SPEAKER VOLUME IS ALREADY AT MAXIMUM VOLUME AND IS NOT
ADJUSTABLE.
In cases where the RSS/FSS give warnings but nothing is within range of the vehicle sensors, or
give warnings for 3 seconds then ceases, the occurrence may be due to any of the following
reasons:
BLOCKED/CONTAMINATED PROXIMITY SENSOR
SURFACE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings >
Page 9961
Proximity sensor surfaces may be covered with snow, ice, dirt or mud. There is a gap between the
sensor membrane and its plastic housing that must remain clear (Figure 1). If this space is
contaminated with any foreign material the system may sound a continuous tone or intermittent
tone. The sensor surface can be cleaned by a high pressure water spray.
SIDE COVERAGE SENSOR:
There is side/rear coverage that extends approximately 18" (46 cm) perpendicular from the side
rear fascia. Side coverage is a desirable feature in a parking situation where the vehicle is involved
in a very tight turn with little rearward movement, or where the vehicle is backing parallel to a large,
extending obstacle such as a garage wall. If there is no encroachment between any of the outer
sensors and an obstacle, then the warning will sound for 3 seconds and cease. If vehicle or the
obstacle begin to move closer to each other, then the warning will begin again. Obstacles within
10" (25 cm) of the fascia will always be reported with a continuous tone. This is considered normal
operation.
ABNORMAL ROAD SURFACES:
The RSS/FSS may give warnings due to certain road surfaces with surface projections such as
rocks, broken pavement, unplowed snow covered roads. This is considered normal operation.
OTHER POSSIBLE CAUSES:
Very wet weather conditions, such as mist, frost or snow may provoke occasional warnings. The
system may detect liftgate while open and certain trailer hitches and/or bicycle racks. External
ultrasonic noise may be detected (high velocity air, machinery). This is considered normal
operation.
SENSOR DIAGNOSTICS
1. Ensure that nothing is in detectable sensor-range 6' (1.8 meters) behind vehicle for the RSS and
within 6' (1.8 meters) of the front of the vehicle for the FSS.
2. Clean proximity sensors with a dry shop towel, and if required wash with water or a high
pressure water wash to ensure that the membrane gap is free of any dirt or contamination.
3. Using the New Generation Star (NGS) tester or WDS, observe the following four (4) parking aid
module parameter identification displays (PIDs) for distance information:
^ LR_CNTD (NGS)/LRI_DIST (WDS): (Left Rear Center Sensor Distance To Obstacle)
^ RR_CNTD (NGS)/RRI_DIST (WDS): (Right Rear Center Sensor Distance To Obstacle)
^ LR_CNRD (NGS)/LRO_DIST (WDS): (Left Rear Corner Sensor Distance To Obstacle)
^ RR_CNRD (NGS)/RRO_DIST (WDS): (Right Rear Corner Sensor Distance To Obstacle)
NOTE
PID IDENTIFIERS ALSO EXIST FOR FRONT SENSORS IF EQUIPPED.
a. If the sensor is functioning properly, with no objects in range of the vehicle, each sensor PID as
described above should display a full scale numerical reading of 255 cm (NGS) or 100 inches
(NGS+ and WDS).
b. If a PID reading other than 255 or 100 displays, replace only the sensor that is out of
specification. Refer to Workshop Manual Section 413-00 as needed for removal and installation
procedures.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Parking Assist Distance Sensor: > 05-4-18 > Mar > 05 > Parking Assist System - False Warnings >
Page 9962
ACCESSING PIDS WITH NGS, SELECT:
^ Vehicle Line
^ Diagnostic Data Link
^ PAM
^ PID/Data Monitor And Record
^ Select the appropriate PIDS
^ Start
ACCESSING PIDS WITH WDS, START VEHICLE SESSION THEN SELECT:
^ Toolbox Icon
^ Datalogger, Then Tick (Check Mark)
^ Modules, Then Tick
^ PAM, Then Tick
^ Select The Appropriate PIDS, Then Tick
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
15K859 42
Disclaimer
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Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9963
Parking Assist Distance Sensor: Specifications
Azimuth System Check Object Position 1 (P1) and Position 5 (P5), Distance From Sensor 90 cm
Azimuth System Check Object Position 2 (P2), 3 (P3) and Position 4 (P4), Distance From Sensor
160 cm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9964
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Distance Sensor > Component Information > Technical Service Bulletins > Page 9965
Parking Assist Distance Sensor: Service and Repair
REMOVAL
1. Remove the rear bumper.
2. Remove the parking aid sensor.
1 Disconnect the electrical connector.
2 Release the tabs.
3 Remove the parking aid sensor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Switch > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Switch > Component Information > Diagrams > Page 9969
Parking Assist Switch: Service and Repair
REMOVAL
1. Remove the audio unit. For additional information, refer to Radio, Stereo, and Compact Disc.
2. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel.
^ Disconnect the electrical connector.
3. Remove the hood latch release handle.
1 Remove the screws.
2 Remove the hood latch release handle.
4. Remove the instrument panel lower steering column cover.
1 Remove the screws.
2 Remove the instrument panel lower steering column cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Parking Assist Switch > Component Information > Diagrams > Page 9970
5. Remove the instrument panel steering column opening cover reinforcement.
1 Remove the screws.
2 Remove the instrument panel steering column opening cover reinforcement.
6. If equipped, position the column gearshift lever aside.
7. Remove the instrument cluster finish panel.
1 Remove the screws.
2 Remove the instrument cluster finish panel. ^
Disconnect the electrical connector.
8. Remove the parking aid switch.
1 Remove the screws.
2 Remove the parking aid switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Service and Repair
Remote Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the steering wheel controls.
1 Carefully remove the steering wheel controls.
2 Disconnect the steering wheel controls.
NOTE: The steering wheel is leather wrapped and should be protected when removing the steering
wheel controls.
INSTALLATION
1. Install the steering wheel controls.
1 Connect the steering wheel controls.
2 Install the steering wheel controls.
2. Connect the battery ground cable.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9979
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9980
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9981
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9982
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9983
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9984
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9985
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9986
Trailer Connector: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9987
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9988
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9989
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9990
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9991
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9992
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9993
Trailer Connector: Electrical Diagrams
Diagram 95-1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 9994
Diagram 95-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the trailer tow lights. 2. Verify the exterior lighting
system of the vehicle is operating properly. If not, refer to the appropriate pinpoint test. 3. Visually
inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) Fuse 3 (7.5 A)
^ CJB Fuse 7 (7.5 A)
^ CJB Fuse 30 (15 A)
^ Loose or corroded connections
^ Damaged circuity
^ Damaged relays
^ Failed bulb(s)
4. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See:
Symptom Related Diagnostic Procedures
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 9999
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10000
Trailer Lamps: Pinpoint Tests
Connector Circuit Reference
Refer to the Vehicle/Diagrams for schematic and connector information.
AA1 - AA2
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10001
AB1 - AB2
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10002
AC1
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10003
AD1
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10004
AE1 - AE2
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Ford Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Lamps > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 10005
73 Digital Multimeter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10010
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10011
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10012
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10013
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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> Diagram Information and Instructions > Page 10014
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Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10015
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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> Diagram Information and Instructions > Page 10016
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10017
Trailer Connector: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10018
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10019
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10020
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10021
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10022
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10023
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10024
Trailer Connector: Electrical Diagrams
Diagram 95-1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information > Diagrams
> Diagram Information and Instructions > Page 10025
Diagram 95-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair
Front Bumper Cover / Fascia: Service and Repair
FRONT BUMPER COVER
Removal and Installation
1. Remove the radiator grille sight shield.
1. Remove the bolts. 2. Release the retaining clips. 3. Remove the radiator grille sight shield.
2. Remove the two parking lamp assemblies.
1. Remove the two bolts (one each side). 2. Remove the two parking lamp assemblies.
- Disconnect the electrical connectors.
3. Remove the two headlamp assemblies.
1. Pull upward to release the four tabs (two each side). 2. Remove the two headlamp assemblies.
- Disconnect the electrical connectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System
Information > Service and Repair > Page 10032
4. Remove the three lower radiator air deflector bolts.
5. Remove the six fender splash shield screws (three each side).
6. Remove the two front bumper cover bolts from inside the fender opening (one each side).
7. Remove the front bumper cover.
- Unclip the six locking tabs.
8. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System
Information > Service and Repair
Front Bumper Reinforcement: Service and Repair
FRONT BUMPER
Removal and Installation
1. Remove the front bumper cover.
2. If equipped, remove the two fog lamp assemblies.
1. Disconnect the electrical connectors. 2. Remove the six bolts (three each side). 3. Remove the
two fog lamp assemblies.
3. WARNING: To avoid possible injury, support the front bumper before removing the nuts.
Remove the four nuts (two each side) and the front bumper.
4. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair
Rear Bumper Cover / Fascia: Service and Repair
REAR BUMPER COVER
Special Tool(s)
Special Tool(s)
Removal and Installation
1. Disconnect the two license plate lamps.
2. Remove the four splash shield screws (two each side).
3. Remove the two rear bumper cover rivets (one each side).
4. NOTE: Align the rear bumper cover to the rear bumper beam guide holes when installing the
step pads
Remove the two step pads (one each side).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information
> Service and Repair > Page 10040
5. Remove the rear bumper cover. 6. To install, reverse the removal procedure.
- Using the special tool, install the new rivets.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Disconnect the driver side windshield washer hose from inside the engine compartment.
2. Remove the windshield wiper pivot arms.
1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull
the windshield wiper pivot arm from the windshield wiper pivot shaft.
3. Remove the cowl grille screw.
4. Remove the driver side cowl grille.
- Pull up on the cowl grille to disengage the clips.
5. Remove the passenger side cowl grille.
- Pull up on the cowl grille to disengage the clips and disconnect the washer hose.
6. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
Heavy Duty Riveter
SPECIAL SERVICE TOOLS
REMOVAL
NOTE: Front door shown, rear door similar.
1. Remove the door trim panel. 2. Remove the watershield.
3. Remove the outside door handle.
1 Disconnect the front door latch to door handle rod.
2 Drill out the two rivets and remove the outside door handle.
NOTE: The front door window glass must be completely up.
INSTALLATION
1. To install, reverse the removal procedure.
- Use Heavy-Duty Riveter to install the rivets.
NOTE: Front door shown, rear door similar.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair > Page 10052
Heavy Duty Riveter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Interior Handle > System Information > Service and Repair
Front Door Interior Handle: Service and Repair
REMOVAL
NOTE: Front door shown, rear door similar.
1. Remove the door trim panel.
2. Disconnect the inside door handle from the door.
1 Remove the screws.
2 Disconnect the inside door handle.
3. Disconnect the rod from the inside door handle.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Front door shown, rear door similar.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Specifications
Front Door Latch: Specifications
Door Latch Screws 4-8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Specifications > Page 10059
Door Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Specifications > Page 10060
Door Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Specifications > Page 10061
Front Door Latch: Service and Repair
REMOVAL
NOTE: Front door shown, rear door similar.
1. Disconnect the battery ground cable. 2. If removing the front door latch, remove the door lock
cylinder; refer to Lock Cylinder-Door. 3. Remove the door trim panel.
4. Remove the door latch remote control.
1 Remove the screws.
2 Disconnect the door latch remote control link from the door latch remote control.
3 Remove the door latch remote control.
5. Disconnect the door latch actuating rod from the door latch.
6. Remove the rear glass run channel.
1 Remove the bolt.
2 Remove the rear glass run channel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Specifications > Page 10062
7. Remove the door latch.
1 Remove the screws.
2 Disconnect the door latch from the power door lock actuator.
3 Remove the door latch.
8. Disconnect the door latch push button rod from the door latch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Front door shown, rear door similar.
- Connect the remote control rod, door latch push button rod and lock cylinder rod to the front door
latch before installing the new latch.
- When the battery is disconnected or reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System
Information > Specifications > Page 10063
The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair
Front Door Panel: Service and Repair
TRIM PANEL - FRONT DOOR
Removal
NOTE: High series shown, low series similar.
- The window must be completely down to remove the front door trim panel.
1. On high series front door trim panel, disconnect the battery ground cable (14301).
2. Remove the screws.
3. Remove the inside door handle cup (22634).
4. On low series front door trim panel, remove the screw and the window regulator handle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System
Information > Service and Repair > Page 10067
5. Start in a lower corner and work around the panel and separate the front door trim panel (23942)
from the front door (20124) to disengage the
pin-type retainers.
6. Lift the front door trim panel to disengage the top lip from the weatherstrip. 7. Position the front
door trim panel aside.
8. Separate the power window switch finish panel from the door trim panel.
- Release the locking tabs.
9. If equipped, remove the courtesy lamp bulb from the lens and remove the front door trim panel.
Installation
1. NOTE: When the battery (10653) is disconnected and reconnected, some abnormal drive
symptoms may occur while the vehicle relearns its
adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Service and Repair
Front Door Window Glass: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the front door trim panel.
2. Remove the inside glass weatherstrip.
3. Drill out the window regulator arm to window glass rivets.
NOTE: Lower the window glass to access the two rivets.
4. Remove the front door window glass.
NOTE: Slide the glass through the outboard side of the front door.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass >
System Information > Service and Repair > Page 10071
INSTALLATION
1. Position the front door window glass.
NOTE: Slide the glass through the outboard side of the front door.
2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets.
3. Install the inside glass weatherstrip. 4. Install the front door trim panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Specifications
Front Door Window Motor: Specifications
Power Window Motor Nuts 5.6-9.1 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Specifications > Page 10075
Front Door Window Motor: Service Precautions
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Specifications > Page 10076
Front Door Window Motor: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOLS
REMOVAL
1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3.
Disconnect the battery ground cable.
4. Disconnect the inside front door handle from the front door.
1 Remove the screws.
2 Disconnect the inside front door handle.
5. Disconnect the rod from the inside front door handle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Specifications > Page 10077
6. Support the front door window glass.
7. If equipped, disconnect the power window motor electrical connector.
8. If equipped, remove the equalizer bracket to front door inner panel nuts.
9. Remove the window regulator/motor assembly.
1 Drill out the rivets.
2 Remove the nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Specifications > Page 10078
10. If equipped, remove the power window motor.
1 Remove the bolts.
2 Remove the power window motor.
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Specifications > Page 10079
1. To install, reverse the removal procedure.
^ Use Heavy Duty Riveter to install the new rivets.
^ Cycle the door glass to ensure engagement of the drive mechanism.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor >
Component Information > Specifications > Page 10080
Heavy Duty Riveter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Specifications
Front Door Window Regulator: Specifications
Rear Window Glass Regulator Nut 10-14 Nm
Window Regulator Switch Plate Harness Assembly 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Specifications > Page 10084
Front Door Window Regulator: Service Precautions
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Specifications > Page 10085
Front Door Window Regulator: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOLS
Motor and Window Regulator - Front Door
REMOVAL
1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3.
Disconnect the battery ground cable.
4. Disconnect the inside front door handle from the front door.
1 Remove the screws.
2 Disconnect the inside front door handle.
5. Disconnect the rod from the inside front door handle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Specifications > Page 10086
6. Support the front door window glass.
7. If equipped, disconnect the power window motor electrical connector.
8. If equipped, remove the equalizer bracket to front door inner panel nuts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Specifications > Page 10087
9. Remove the window regulator/motor assembly.
1 Drill out the rivets.
2 Remove the nut.
10. If equipped, remove the power window motor.
1 Remove the bolts.
2 Remove the power window motor.
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Specifications > Page 10088
1. To install, reverse the removal procedure.
^ Use Heavy Duty Riveter to install the new rivets.
^ Cycle the door glass to ensure engagement of the drive mechanism.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window
Regulator > System Information > Specifications > Page 10089
Heavy Duty Riveter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Exterior Handle > System Information > Service and Repair
Rear Door Exterior Handle: Service and Repair
Heavy Duty Riveter
SPECIAL SERVICE TOOLS
REMOVAL
NOTE: Front door shown, rear door similar.
1. Remove the door trim panel. 2. Remove the watershield.
3. Remove the outside door handle.
1 Disconnect the front door latch to door handle rod.
2 Drill out the two rivets and remove the outside door handle.
NOTE: The front door window glass must be completely up.
INSTALLATION
1. To install, reverse the removal procedure.
- Use Heavy-Duty Riveter to install the rivets.
NOTE: Front door shown, rear door similar.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear
Door Interior Handle > System Information > Service and Repair
Rear Door Interior Handle: Service and Repair
REMOVAL
NOTE: Front door shown, rear door similar.
1. Remove the door trim panel.
2. Disconnect the inside door handle from the door.
1 Remove the screws.
2 Disconnect the inside door handle.
3. Disconnect the rod from the inside door handle.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Front door shown, rear door similar.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Specifications
Rear Door Latch: Specifications
Door Latch Screws 4-8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Specifications > Page 10101
Door Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Specifications > Page 10102
Rear Door Latch: Service and Repair
REMOVAL
NOTE: Front door shown, rear door similar.
1. Disconnect the battery ground cable. 2. If removing the front door latch, remove the door lock
cylinder; refer to Lock Cylinder-Door. 3. Remove the door trim panel.
4. Remove the door latch remote control.
1 Remove the screws.
2 Disconnect the door latch remote control link from the door latch remote control.
3 Remove the door latch remote control.
5. Disconnect the door latch actuating rod from the door latch.
6. Remove the rear glass run channel.
1 Remove the bolt.
2 Remove the rear glass run channel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Specifications > Page 10103
7. Remove the door latch.
1 Remove the screws.
2 Disconnect the door latch from the power door lock actuator.
3 Remove the door latch.
8. Disconnect the door latch push button rod from the door latch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Front door shown, rear door similar.
- Connect the remote control rod, door latch push button rod and lock cylinder rod to the front door
latch before installing the new latch.
- When the battery is disconnected or reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System
Information > Specifications > Page 10104
The vehicle may need to be driven 16km (10 mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair
Rear Door Panel: Service and Repair
TRIM PANEL - REAR DOOR
Removal
NOTE: High series shown, low series similar.
- The window glass must be completely down to remove the rear door trim panel.
1. Remove the screws.
2. Remove the inside door handle cup.
3. On low series rear door trim panel, remove the window regulator handle.
- Remove the screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System
Information > Service and Repair > Page 10108
4. Start in a lower corner and work around the panel and separate the rear door trim panel from the
rear door to disengage the pin-type retainers.
5. Remove the rear door trim panel by lifting to disengage the top lip from the weatherstrip. 6. Turn
the rear door trim panel over.
7. Disconnect the power window switch electrical connector.
1. Remove the screws. 2. Disconnect the electrical connector.
Installation
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair
Rear Door Window Glass: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the rear door trim panel.
2. Remove the inside glass weatherstrip.
3. Drill out the window regulator arm to window glass rivets.
4. Remove the rear door window glass.
NOTE: Slide the glass through the outboard side of the rear door.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass >
System Information > Service and Repair > Page 10112
1. Position the rear door window glass.
NOTE: Slide the glass through the outboard side of the rear door.
2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets.
3. Install the inside glass weatherstrip. 4. Install the rear door trim panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Specifications
Rear Door Window Motor: Specifications
Power Window Motor Nuts 5.6-9.1 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Specifications > Page 10116
Rear Door Window Motor: Service Precautions
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Specifications > Page 10117
Rear Door Window Motor: Service and Repair
REMOVAL
1. Raise and support the rear door window glass to the full up position. 2. Disconnect the battery
ground cable. 3. Remove the rear door trim panel.
4. Remove the speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
5. Remove the watershield.
6. Remove the power window motor.
1 Remove the bolts.
2 Disconnect the electrical connector.
3 Remove the power window motor.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Specifications > Page 10118
1. To install, reverse the removal procedure.
^ Cycle the door glass to ensure engagement of the drive mechanism.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Motor >
Component Information > Specifications > Page 10119
Heavy Duty Riveter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Specifications
Rear Door Window Regulator: Specifications
Rear Window Glass Regulator Nut 10-14 Nm
Window Regulator Switch Plate Harness Assembly 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Specifications > Page 10123
Rear Door Window Regulator: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOLS
REMOVAL
1. Remove the rear door trim panel.
2. Disconnect the inside rear door handle from the rear door.
1 Remove the screws.
2 Disconnect the inside rear door handle.
3. Disconnect the rod from the inside rear door handle.
4. Remove the speaker.
1 Remove the screws.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Specifications > Page 10124
2 Disconnect the electrical connector.
3 Remove the speaker.
5. Remove the watershield. 6. Raise and support the rear door window glass to the full up position.
7. Disconnect the battery ground cable.
8. If equipped, disconnect the power window electrical connector.
9. Drill out the window regulator rivets.
10. Remove the rear door window regulator.
^ Slide the regulator arms off of the window glass track.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Specifications > Page 10125
1. To install, reverse the removal procedure.
^ Use Heavy Duty Riveter to install the new rivets.
^ Cycle the door glass to ensure engagement of the drive mechanism.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator
> System Information > Specifications > Page 10126
Heavy Duty Riveter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Specifications
Hood Latch: Specifications
Hood Latch Bolts 10.5-13.5 Nm
Hood Latch Control Handle Screws 2-4 Nm
Hood Latch Release Handle Screws 2.7-3.7 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Specifications > Page 10131
Hood Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Specifications > Page 10132
Hood Latch: Adjustments
1. Verify the hood alignment.
2. Remove the radiator grille sight shield.
1 Remove the bolts.
2 Remove the rivets.
3 Remove the radiator grille sight shield.
3. Align the hood latch.
1 Loosen the hood latch bolts enough to allow for movement of the hood latch.
2 Align the hood latch with the hood latch striker.
4. Tighten the hood latch bolts. 5. Verify the hood latch striker is fully engaging the hood latch.
- Repeat the procedure as necessary.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Specifications > Page 10133
Hood Latch: Service and Repair
REMOVAL
1. Raise and support the hood.
2. Remove the radiator grille sight shield.
1 Remove the bolts.
2 Remove the rivets.
3 Remove the radiator grille sight shield.
3. Remove the hood latch.
1 Remove the bolts.
2 Disconnect the hood latch cable from the hood latch.
3 Remove the hood latch.
NOTE: Mark the hood latch position prior to removal of the bolts.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information >
Specifications > Page 10134
1. To install, reverse the removal procedure.
- Adjust the hood latch; refer to Latch-Hood, Adjustment. See: Adjustments
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component
Information > Locations
Hood Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component
Information > Locations > Page 10138
Hood Latch Release Cable: Service and Repair
REMOVAL
NOTE: The hood latch control handle and cable are replaced as an assembly.
1. Remove the hood latch. For additional information, refer to Hood Latch.
2. Unclip the hood latch control handle and cable retainer from the inner fender splash shield.
3. Position the hood latch control handle and cable aside.
1 Remove the two screws.
2 Position the hood latch control handle and cable aside.
4. Remove the hood latch control handle and cable.
1 Remove the hood latch control and cable grommet from the dash panel.
2 Remove the hood latch control handle and cable.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component
Information > Locations > Page 10139
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 10145
OASIS CODES: 201000, 201200
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass >
Component Information > Service and Repair
Liftgate Window Glass: Service and Repair
REMOVAL
1. Open the liftgate glass.
2. Disconnect the two rear window defogger electrical connectors (one on each side).
3. Disconnect the two liftgate cylinders (one on each side).
4. Release the upper liftgate trim panel clips to gain access to liftgate window glass access plugs.
5. Remove the liftgate glass hinge access plugs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Liftgate Window Glass >
Component Information > Service and Repair > Page 10150
6. Remove the liftgate window glass.
1 Remove the two liftgate window glass to window hinge nuts.
2 Remove the liftgate window glass.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations
Liftgate Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Page 10154
Power Trunk / Liftgate Lock Actuator: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the liftgate window latch. For additional
information, refer to Liftgate Window Latch.
3. Remove the vent panel.
1 Remove the pin-type retainers.
2 Remove the vent panel.
4. Disconnect the liftgate latch release rods.
1 Open the clips.
2 Disconnect the liftgate latch release rods.
5. Disconnect the liftgate handle rod.
1 Open the clip.
2 Disconnect the liftgate handle rod.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Page 10155
6. Disconnect the lock cylinder rod.
1 Open the clip.
2 Disconnect the lock cylinder rod.
7. Remove the liftgate latch remote control bolt.
8. Disconnect the liftgate lock actuator electrical connector.
9. Remove the liftgate lock actuator nuts.
10. Move the liftgate latch remote control to the LH opening and remove the liftgate lock actuator.
INSTALLATION
1. Connect and position the liftgate lock actuator.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Page 10156
2. Install the liftgate lock actuator nuts.
3. Connect the liftgate lock actuator electrical connector. 4. Position the liftgate latch remote
control.
5. Loosely install the liftgate latch remote control bolt.
6. Install the liftgate window latch.
1 Position the liftgate window latch.
2 Install the nuts.
3 Connect the electrical connector.
NOTE: Manually close the liftgate window latch to set the latch control rod length.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Page 10157
7. Connect the liftgate window latch actuating rod.
1 Position the liftgate window latch actuating rod.
2 Close the clip.
8. Tighten the liftgate latch remote control bolt.
9. Connect the lock cylinder rod.
1 Position the lock cylinder rod.
2 Close the clip.
NOTE: Be sure the bell crank of the liftgate latch remote control is in the unlocked position
(upward) for proper lock cylinder rod length.
10. Connect the liftgate handle rod.
1 Position the liftgate handle rod.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock
Actuator > Component Information > Locations > Page 10158
2 Close the clip.
NOTE: Make sure the liftgate handle rod is not preloading the liftgate latch remote control. It should
be clipped in a relaxed state with no slack.
11. Connect the liftgate latch release rods.
1 Position the liftgate latch release rods by pushing outboard to remove the slack.
2 Close the clips.
NOTE: Make sure the latch release rods are not pre loading the liftgate latch. They should be
clipped in a relaxed state with no slack.
12. Install the vent panel.
1 Position the vent panel.
2 Install the pin-type retainers.
13. Adjust the liftgate window latch. For additional information, refer to Liftgate Latch, Adjustment.
See: Trunk / Liftgate Latch/Adjustments
14. Install the liftgate watershield. 15. Install the liftgate trim panel. 16. Connect the battery ground
cable.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Locations
Liftgate Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Locations > Page 10162
Trunk / Liftgate Handle: Service and Repair
Heavy Duty Riveter
SPECIAL SERVICE TOOLS
REMOVAL
1. Remove the liftgate trim panel.
2. Remove the liftgate watershield.
3. Remove the vent panel.
1 Remove the pin-type retainers.
2 Remove the vent panel.
4. Disconnect the outside liftgate handle actuating rod.
1 Open the clip.
2 Disconnect the outside liftgate handle actuating rod.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Locations > Page 10163
5. Remove the license plate lamp shield
1 Remove the screws.
2 Remove the license plate lamp shield.
6. Remove the outside liftgate handle.
1 Drill out the rivets.
2 Remove the outside liftgate handle.
INSTALLATION
1. To install, reverse the removal procedure. Use Heavy-Duty Riveter to install the rivets.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Handle >
Component Information > Locations > Page 10164
Heavy Duty Riveter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Specifications
Trunk / Liftgate Latch: Specifications
Liftgate Latch Bolt 9-14 Nm
Liftgate Latch Remote Control 11-13 Nm
Liftgate Window Latch Nuts 12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Specifications > Page 10168
Liftgate Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Specifications > Page 10169
Trunk / Liftgate Latch: Adjustments
1. Remove the liftgate trim panel.
2. Remove the liftgate watershield. 3. Close the liftgate window glass.
4. Disconnect the liftgate window latch actuating rod.
1 Open the clip.
2 Disconnect the liftgate window latch actuating rod.
5. Loosen the liftgate window latch nuts.
6. Adjust the liftgate window latch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Specifications > Page 10170
- Set the liftgate window glass flushness to 1.5 mm (0.06 in) under flush.
7. Tighten the liftgate window latch nuts.
8. Connect the liftgate window latch activating rod.
1 Connect the liftgate window latch actuating rod.
2 Lock the clip.
9. Verify the liftgate window glass flushness.
10. Install the liftgate watershield. 11. Install, the liftgate trim panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch
Trunk / Liftgate Latch: Service and Repair Liftgate Latch
REMOVAL
1. Remove the liftgate trim panel.
2. Remove the liftgate watershield.
3. Disconnect the liftgate latch release rod from the liftgate latch remote control.
1 Open the clip.
2 Disconnect the liftgate latch release rod.
4. Remove the liftgate latch.
1 Remove the bolts.
2 Disconnect the electrical connector.
3 Remove the liftgate latch and the liftgate release rod.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 10173
1. To install, reverse the removal procedure.
NOTE: If replacement of the liftgate latch release rods necessary, be sure to match the color coded rods
for proper installation.
- Make sure the liftgate latch release rod is not preloading the latch. It should be clipped in a
relaxed state with no slack.
- Position the liftgate latch release rod by pushing outboard to remove the slack.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 10174
Trunk / Liftgate Latch: Service and Repair Liftgate Latch Remote Control
REMOVAL
NOTE: If equipped with power locks, perform steps one and eight.
1. Remove the liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator. 2.
Remove the liftgate window latch. For additional information, refer to Liftgate Latch.
3. Remove the vent panel.
1 Remove the pin-type retainers.
2 Remove the vent panel.
4. Disconnect the liftgate latch release rods.
1 Open the clips.
2 Disconnect the liftgate latch release rods.
5. Disconnect the liftgate handle rod.
1 Open the clip.
2 Disconnect the liftgate handle rod.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 10175
6. Disconnect the lock cylinder rod.
1 Open the clip.
2 Disconnect the lock cylinder rod.
7. Remove the liftgate latch remote control bolt. 8. Remove the liftgate latch remote control from
the liftgate.
INSTALLATION
NOTE: If equipped with power locks, perform steps one and two.
1. Install the latch remote control and (if equipped) the push button rod into the liftgate. 2. Install the
liftgate lock actuator. For additional information, refer to Liftgate Lock Actuator.
3. Loosely install the liftgate latch remote control bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 10176
4. Install the liftgate window latch.
1 Position the liftgate window latch.
2 Install the nuts.
3 Connect the electrical connector.
NOTE: Manually close the liftgate window latch to set the latch control rod length.
5. Connect the liftgate window latch actuating rod.
1 Position the liftgate window latch actuating rod.
2 Close the clip.
6. Tighten the liftgate latch remote control bolt.
7. Connect the lock cylinder rod.
1 Position the lock cylinder rod.
2 Close the clip.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 10177
8. Connect the liftgate handle rod.
1 Position the liftgate handle rod.
2 Close the clip.
NOTE: Make sure the liftgate handle rod is not preloading the liftgate latch remote control. It should
be clipped in a relaxed state with no slack.
9. Connect the liftgate latch release rods.
1 Position the liftgate latch release rods by pushing outboard to remove the slack.
2 Close the clips.
NOTE: Make sure the latch release rods are not preloading the liftgate latch remote control. They
should be clipped in a relaxed state with no slack.
10. Install the vent panel.
1 Position the vent panel.
2 Install the pin-type retainers.
11. Adjust the liftgate window latch. For additional information, refer to Liftgate Window Latch,
Adjustment. See: Adjustments
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 10178
12. Install the liftgate watershield. 13. Install the liftgate trim panel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 10179
Trunk / Liftgate Latch: Service and Repair Liftgate window Latch
REMOVAL
1. Open the liftgate window glass. 2. Remove the liftgate trim panel.
3. Remove the liftgate watershield.
4. Disconnect the liftgate window latch actuating rod.
1 Open the clip.
2 Disconnect the liftgate window latch actuating rod.
5. Disconnect the electrical connector and remove the nuts.
NOTE: Mark the position of the liftgate window latch prior to removing the nuts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch >
Component Information > Service and Repair > Liftgate Latch > Page 10180
6. Remove the liftgate window latch.
INSTALLATION
1. To install, reverse the removal procedure. Before installing the liftgate trim panel, adjust the
liftgate window latch; refer to Liftgate Window
Latch, Adjustment. See: Adjustments
NOTE: Manually close the liftgate window latch to set the latch control rod length.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Specifications
Trunk / Liftgate Lock Cylinder: Specifications
Liftgate Lock Cylinder Nuts 6-7 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Specifications > Page 10184
Liftgate Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder >
Component Information > Specifications > Page 10185
Trunk / Liftgate Lock Cylinder: Service and Repair
REMOVAL
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. If equipped, remove the liftgate lock actuator. For additional information, refer to Liftgate Lock
Actuator. 2. Remove the liftgate latch remote control. For additional information, refer to Liftgate
Latch.
3. Remove the liftgate lock cylinder.
1 Remove the nuts.
2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Manually close the liftgate window latch to set the latch control rod length.
- Make sure the liftgate window latch actuating rod is not preloading the liftgate window latch. It
should be clipped in a relaxed state with no slack.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 10189
Trunk / Liftgate Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 10190
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information >
Service and Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Disconnect the driver side windshield washer hose from inside the engine compartment.
2. Remove the windshield wiper pivot arms.
1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull
the windshield wiper pivot arm from the windshield wiper pivot shaft.
3. Remove the cowl grille screw.
4. Remove the driver side cowl grille.
- Pull up on the cowl grille to disengage the clips.
5. Remove the passenger side cowl grille.
- Pull up on the cowl grille to disengage the clips and disconnect the washer hose.
6. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair
Front Fender Liner: Service and Repair
FENDER SPLASH SHIELD
Removal and Installation
Both Sides
1. Remove the fender splash shield front bolts.
2. Remove the fender splash shield screws.
LH Side
3. From inside the engine compartment, disconnect the wiring harness retainers from the fender
splash shield.
4. Remove the ABS module nut.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service
and Repair > Page 10200
RH Side
5. Position the vacuum reservoir aside.
1. Remove the bolts. 2. Position the vacuum reservoir aside.
6. Remove the fender splash shield bolts.
Both Sides
7. Remove the fender splash shield. 8. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1
Body / Frame Mount Bushing: Service and Repair Body Support - Number 1
BODY SUPPORT - NUMBER 1
Materials
Material
Removal and Installation
NOTE: Left side shown, right side similar.
Upper and Lower Insulator
1. Remove the door scuff plate.
2. Remove the A-pillar lower trim panel.
1. Remove the pin-type retainer. 2. Remove the A-pillar lower trim panel.
3. Position back the carpeting and remove the body insulator plug.
4. NOTE: This step may require holding the lower retainer with an appropriate tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 10206
Remove the body mount insulator bolt.
5. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on
the body mount bolt head with a hammer.
Remove the lower body mount insulator.
Upper Insulator
6. Loosen, but do not remove, all the remaining body mount insulator bolts.
7. Carefully raise the vehicle body enough to remove the upper body mount insulator.
Upper and Lower Insulator
8. NOTE:
- Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent
to the mounting bolt.
- No lubricants of any kind are to be used during body insulator installation.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 10207
Body / Frame Mount Bushing: Service and Repair Body Support - Number 2
BODY SUPPORT - NUMBER 2
Materials
Material
Removal and Installation
NOTE: Left side shown, right side similar.
Upper and Lower Insulator
1. Position the front seat forward. 2. Remove the door scuff plates.
3. Position back the carpeting and remove the body insulator plug.
4. NOTE: This step may require holding the lower retainer with an appropriate tool.
Remove the body mount insulator bolt.
5. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on
the body mount bolt head with a hammer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 10208
Remove the lower body mount insulator.
Upper Insulator
6. Loosen, but do not remove, all the remaining body mount insulator bolts.
7. Carefully raise the vehicle body enough to remove the upper body mount insulator.
Upper and Lower Insulator
8. NOTE:
- Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent
to the mounting bolt.
- No lubricants of any kind are to be used during body insulator installation.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 10209
Body / Frame Mount Bushing: Service and Repair Body Support - Number 3
BODY SUPPORT - NUMBER 3
Materials
Material
Removal and Installation
NOTE: Left side shown, right side similar.
Upper and Lower Insulator - All Vehicles
1. Fold the rear seat forward.
Upper and Lower Insulator - Explorer Sport
2. Position the carpet aside.
Upper and Lower Insulator - Sport Trac
3. Open the storage compartment.
Upper and Lower Insulator - All Vehicles
4. Remove the body insulator plug
5. NOTE: This step may require holding the lower retainer with an appropriate tool.
Remove the body mount insulator bolt.
Lower Insulator - All Vehicles
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 10210
6. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on
the body mount bolt head with a hammer.
Remove the lower body mount insulator.
Upper Insulator - All Vehicles
7. Carefully raise the vehicle body enough to remove the upper body mount insulator.
Upper and Lower Insulator - All Vehicles
8. NOTE:
- Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent
to the mounting bolt.
- No lubricants of any kind are to be used during body insulator installation.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 10211
Body / Frame Mount Bushing: Service and Repair Body Support - Number 4
BODY SUPPORT - NUMBER 4
Materials
Material
Removal and Installation
NOTE: Left side shown, right side similar.
Upper and Lower Insulator
1. Remove the liftgate scuff plate.
1. Release the locking tabs. 2. Remove the scuff plate.
2. NOTE: This step may require holding the lower retainer with an appropriate tool.
Position back the carpeting and remove the body mount insulator bolt.
3. NOTE: If the lower body mount will not remove, loosely install the body mount bolt and tap on
the body mount bolt head with a hammer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 10212
Remove the lower body mount insulator.
Upper Insulator
4. Loosen, but do not remove, all the remaining body mount insulator bolts.
5. Carefully raise the vehicle body enough to remove the upper body mount insulator.
Upper and Lower Insulator
6. NOTE:
- Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or equivalent
to the mounting bolt.
- No lubricants of any kind are to be used during body insulator installation.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service
and Repair > Body Support - Number 1 > Page 10213
Body / Frame Mount Bushing: Service and Repair Body Support - Radiator Support
BODY SUPPORT - RADIATOR SUPPORT
Removal and Installation
NOTE: Left side shown, right side similar.
Upper and Lower Insulator
1. From inside the engine compartment, remove the body mount insulator nut and backing plate
and discard the nut.
Lower Insulator
2. Remove the lower radiator body mount.
1. Remove the lower body mount bolt and discard. 2. Remove the lower body mount.
Upper and Lower Insulator
3. Carefully raise the vehicle body enough to remove the upper radiator body mount insulator.
4. NOTE:
- Do not reuse body support mounting fasteners. New fasteners must be installed for each fastener
that has been removed or loosened.
- No lubricants of any kind are to be used during body insulator installation.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Rear Cross-Member > System Information >
Service and Repair
Rear Cross-Member: Service and Repair
CROSSMEMBER - TRANSMISSION SUPPORT
Materials
Materials
Removal and Installation
1. Raise and support the vehicle.
2. Loosen, but do not remove, the nuts retaining the transmission insulator to the crossmember. 3.
Support the transmission.
4. Remove the six bolts retaining the crossmember to the frame.
5. Remove the nuts and the crossmember.
6. NOTE: Apply Threadlock 262 E2FZ-19554-B meeting Ford specification WSK-M2G351-A6 or
equivalent to the transmission crossmember
mounting bolts.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair
Grille: Service and Repair
RADIATOR GRILLE
Removal and Installation
1. Remove the front bumper cover.
2. Remove the radiator grilles.
1. Remove the four pin-type retainers. 2. Release the six clips. 3. Remove the radiator grilles.
3. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications
Console: Specifications
Base Series Floor Console Rear Screw 2-3 Nm
Base Series Floor Console Front Screws 3-4 Nm
Upper Series Floor Console Bolts 9 Nm
Upper Series Floor Console Electrical Connector Bolt 4.0-5.5 Nm
Upper Series Front Floor Console Bolts 3.4-4.6 Nm
Console Compartment Trim Panel Screw 2-3 Nm
Console Glove Compartment Door Hinge Screw 2-3 Nm
Console Rear Panel Screw 1.2-1.8 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications
> Page 10225
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Specifications
> Page 10226
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console, Upper Series
Console: Service and Repair Floor Console, Upper Series
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the front floor console tray.
- If equipped with message center, disconnect the three connectors.
3. Disconnect the floor console electrical connector.
1 Remove the bolt.
2 Disconnect the electrical connector.
4. Remove the front floor console bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console, Upper Series > Page 10229
5. Remove the center cupholder panel.
6. Remove the center floor console bolts.
7. Remove the floor console.
NOTE: The console must be moved rearward to disengage the rear mounting bracket.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console, Upper Series > Page 10230
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console, Upper Series > Page 10231
Console: Service and Repair Floor Console, Base Series
REMOVAL
NOTE: The base floor console is shown; floor console with removable storage bin is similar.
1. Remove the front seat center armrest.
1 Remove the two covers.
2 Remove the four bolts.
3 Remove the armrest.
2. Remove the utility tray beverage holder.
3. Remove the floor console.
1 Remove the screws.
2 Remove the floor console.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console, Upper Series > Page 10232
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Floor Console, Upper Series > Page 10233
Console: Service and Repair Overhead Console
REMOVAL
1. Disconnect the battery ground cable.
2. If equipped, open the garage door remote cover.
3. If equipped, remove the screws.
4. Remove the overhead console.
5. Disconnect the two electrical connectors (three connectors on moonroof equipped vehicles).
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10239
7. Remove the two steering wheel back cover plugs.
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10240
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10241
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10242
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10243
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming
and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 10244
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Prove out the system means to turn the ignition switch from the OFF to the RUN position and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately six seconds and then turn off. If an air bag Supplemental
Restraint System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair
Headliner: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the quarter trim panel. 3. If equipped, remove
the overhead console. 4. Remove the interior lamps.
5. Remove the sun visors.
1 Remove the six screws.
2 Remove the sun visors. If equipped, disconnect the electrical connectors.
6. Remove the sun visor brackets.
1 Remove the two screws.
2 Remove the sun visor brackets.
7. Remove the assist handle bolt covers.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and
Repair > Page 10248
8. Remove the assist handles.
1 Remove the bolts.
2 Remove the assist handles.
9. Remove the headliner pin-type retainers.
10. Remove the six remaining pin-type retainers. 11. Remove the headliner.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and
Repair
Sun Visor: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the sun visor.
- Position the sun visor as necessary.
- Remove the sun visor screws.
3. Lower the sun visor and disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel
Trim Panel: Service and Repair A-Pillar Trim Panel
Special Service Tool(s)
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the windshield side garnish moulding.
2. Remove the front door scuff plate.
1 Starting at one end and working along the front door scuff plate, use Windshield and
Molding/Trim Removal Kit to remove the front door scuff plate.
2 Remove the front door scuff plate from the B-pillar.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10256
3. Remove the (A) screw and the (B) coat hook.
4. Open the front safety belt guide bolt cover.
5. Using special tool, remove the front safety belt guide bolt.
6. Use Safety Belt Bolt Bit to remove the front safety belt anchor bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10257
7. Remove the B-pillar trim panel.
1 Remove the pin-type retainer.
2 Feed the safety belt webbing through the opening.
3 Remove the B-pillar trim panel.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10258
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10259
Trim Panel: Service and Repair Cowl Side Trim Panel
Windshield and Molding/Trim Removal Kit Or Equivalent
Special Service Tool(s)
REMOVAL
NOTE: 4-door shown, 2-door similar.
1. Remove the front door scuff plate.
1 Starting at one end and working along the front door scuff plate, use Windshield and
Molding/Trim Removal Kit to remove the front door scuff plate.
2 Remove the front door scuff plate from the B-pillar.
2. Remove the cowl side trim panel by pulling outward to disengage the pin-type retainers.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10260
Trim Panel: Service and Repair Liftgate Trim Panel
Windshield and Molding/Trim Removal Kit Or Equivalent
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the (A) liftgate handle to liftgate screws and the (B) liftgate handle.
2. Remove the liftgate trim panel screw access plug.
3. Remove the screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10261
4. Remove the liftgate door trim panel.
1 Use Windshield and Molding/Trim Removal Kit to remove the liftgate door trim panel from the
liftgate window opening.
2 Push the liftgate door trim panel toward the top of the liftgate and remove the liftgate trim panel.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10262
Trim Panel: Service and Repair Quarter Trim Panel
Four Door
Special Service Tool(s)
SPECIAL SERVICE TOOL(S)
REMOVAL
1. If equipped, remove the retractable cargo cover.
2. Remove the liftgate scuff plate.
1 Starting at either end and working along the liftgate scuff plate, use Windshield and Molding/Trim
Removal Kit to remove the scuff plate.
2 Remove the liftgate scuff plate.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10263
3. If equipped, remove the rear power lock switch assembly.
- Disconnect the electrical connector.
4. Remove the B-pillar trim panel.
5. Remove the three rear quarter trim panel screws.
- Position the carpet aside to gain access to the screws.
6. Remove the rear safety belt anchor nut.
7. Open the rear safety belt guide bolt cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10264
8. Using the special tool, remove the rear safety belt guide bolt.
9. Remove the quarter trim panel.
1 Remove the pin-type retainers.
2 Feed the safety belt webbing through the opening in the quarter trim panel.
3 Remove the quarter trim panel.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10265
1. Install the quarter trim panel.
1 Feed the safety belt webbing through the opening in the quarter trim panel.
2 Position the quarter trim panel.
3 Install the pin-type retainers.
2. Using the special tool, install the rear safety belt guide bolt.
3. Close the rear safety belt guide bolt cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10266
4. Install the rear safety belt anchor nut.
5. Install the three rear quarter trim panel screws. 6. Install the B-pillar trim panel.
7. Install the liftgate scuff plate.
1 Position the liftgate scuff plate.
2 Start at either end and work along the liftgate scuff plate, pushing it into the floor panel.
8. If equipped, install the retractable cargo cover.
Two Door
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10267
Special Service Tool(s)
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the windshield side garnish moulding. 2. Remove the front door scuff plate.
3. Remove the front safety belt guide bolt cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10268
4. Using the special tool, remove the front safety belt guide bolt.
5. Using the special tool, remove the front safety belt anchor bolt.
6. If equipped, remove the retractable cargo cover.
7. Remove the liftgate scuff plate.
1 Starting at either end and working along the liftgate scuff plate, use Windshield and Molding/Trim
Removal Kit to remove the scuff plate.
2 Remove the liftgate scuff plate.
8. Fold the rear seat into the load floor position.
9. Using the special tool, remove the rear safety belt guide bolt.
- Position the rear safety belt guide cover aside.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10269
10. Using the special tool, remove the rear safety belt anchor bolt.
11. Remove the two rear quarter window latch screws.
12. Remove the coat hook.
1 Remove the screw.
2 Remove the coat hook.
13. Remove the quarter trim panel front screw.
- Position the carpet aside to gain access to the screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10270
14. Remove the three quarter trim panel rear screws.
- Position the carpet aside to gain access to the screws.
15. If equipped, remove the rear power lock switch assembly.
- Disconnect the electrical connector.
16. Remove the quarter trim panel.
1 Remove the eight pin-type retainers.
2 Feed the safety belt webbing through the opening in the quarter trim panel.
3 Remove the quarter trim panel.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and
Repair > A-Pillar Trim Panel > Page 10271
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information >
Service and Repair
Door Lock Cylinder: Service and Repair
REMOVAL
NOTE:
- When a lock cylinder is replaced, both door lock cylinders, liftgate lock cylinders and ignition lock
cylinder should be replaced as a set. This will eliminate carrying an extra key which will fit only one
lock. If a key is to be replaced, the new key code number is stamped on a metal tag attached to the
key.
- Individual lock cylinders are repaired by discarding the inoperative cylinder and building a new
lock cylinder using the appropriate lock repair package. The lock repair package includes a detailed
instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. Remove the front door trim panel. 2. Close the window. 3. Remove the watershield.
4. Disconnect the front door latch control cylinder rod from the door lock cylinder lever.
5. Slide the (A) door lock cylinder retainer away from the (B) lock cylinder and remove the cylinder.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics
Keyless Entry Key-Pad: Technical Service Bulletins Keyless Entry - Keypad Diagnostics
TSB 06-15-8
08/07/06
KEYPAD DIAGNOSTICS - DEALER INSTALLED ACCESSORY
FORD: 1998-2006 Taurus 1999-2003 Escort 1999-2006 Mustang 2000-2006 Focus 2002-2005
Thunderbird 2005-2006 Five Hundred, Freestyle 2006 Crown Victoria, Fusion 1998-2006
Expedition, Explorer, F-150, Ranger 1999 F-250 Light Duty 1999-2003 Windstar 1999-2006
F-Super Duty 2000-2005 Excursion 2000-2006 E-Series 2001-2003 Explorer Sport 2001-2005
Explorer Sport Trac 2001-2006 Escape 2004 F-150 Heritage 2004-2006 Freestar
LINCOLN: 1998-2006 Town Car 2000-2006 Lincoln LS 2006 Zephyr 1998-2006 Navigator
2002-2003 Blackwood 2003-2005 Aviator 2006 Mark LT
MERCURY: 1998-2005 Sable 1999-2002 Cougar 2005-2006 Montego 2006 Grand Marquis, Milan
1998-2006 Mountaineer 2004-2006 Monterey 2005-2006 Mariner
ISSUE Some vehicles may experience a concern with the keyless entry keypad. In order to
properly diagnose the concern with the keyless entry keypad, it is important to identify whether the
keypad is a factory installed style (wired) or a Genuine Ford Accessory (GFA) radio frequency (RF)
style keypad.
ACTION Use the following Service Procedure to identify GFA RF keypads and provide diagnostic
service tips.
SERVICE PROCEDURE
IDENTIFICATION:
1. Production installed keyless entry keypads are mounted flush with the surface of the vehicle and
are wired directly to the module controlling the vehicle's keyless entry system. This style keypad
can be diagnosed using the appropriate Workshop Manual (WSM), Section 501-14.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10282
2. Dealer installed GFA RF keypads are adhesive backed and protrude approximately 1/2" (13
mm) from the surface of the vehicle and there are no specific diagnostics available in the WSM
(Figure 1).
NOTE
THIS RF KEYPAD WAS ALSO US[D IN PRODUCTION ON 2004 F-SUPER DUTY VEHICLES
BUILT PRIOR TO 12/3/2003. REFER TO WSM, SECTION 501-14 FOR RF KEYPAD
DIAGNOSTICS FOR THESE VEHICLES.
GENUINE FORD ACCESSORY KEYPAD DIAGNOSTIC TIPS
1. The keypad operates similarly to a remote keyless entry (RKE) transmitter and is programmed
using a similar procedure.
Although the RF keypad is not specifically addressed in the WSM, the RKE transmitter
programming portion of the WSM, Section 501-14 can be used as a guide
NOTE
THE 7-8 AND 9-0 BUTTONS ON THE KEYPAD MUST BE PRESSED SIMULTANEOUSLY
DURING THE PROCEDURE IN ORDER FOR THE KEYPAD TO BE RECOGNIZED AS AN
ADDITIONAL REMOTE TRANSMITTER.
Since the GFA RF keypad is essentially another RKE transmitter, the transmitter diagnostic
pinpoint tests in the vehicle's WSM can also be referenced even though the buttons serving the
lock / unlock functions will differ
2. The GFA RF keypad is serviced as an assembly. The internal battery cannot be replaced
separately.
3. If the master code or owner selectable code is lost or forgotten, the GFA RF keypad must be
replaced. These codes are not stored in any vehicle module (with the exception of 2004 F-Super
Duty vehicles produced prior to 12/3/2003).
4. The GFA RF keypad and all RKE transmitters (the number of transmitters allowable will vary by
vehicle) must be reprogrammed together anytime the keypad is replaced, an RKE transmitter is
replaced, or the module controlling the keyless entry system on the vehicle (GEM/SJB/VSM/DDM
etc.) is replaced.
NOTE
THERE IS AN EXCEPTION TO TIP 4 FOR VEHICLES EQUIPPED WITH INTEGRATED
KEYHEAD TRANSMITTERS (IKTs) (FUSION/MILAN/ZEPHYR). THE GFA RF KEYPADS FOR
VEHICLES WITH IKTs MUST BE PROGRAMMED INDEPENDENTLY FROM THE IKTs. TURN
THE IGNITION FROM "OFF" TO "RUN" 8 TIMES WITHIN 10 SECONDS, WITH THE 8TH TIME
ENDING IN "RUN". THE DOOR LOCKS WILL CYCLE TO CONFIRM ENTERING
PROGRAMMING MODE. PRESS THE 7-8 AND 9-0 BUTTON ON THE KEYPAD
SIMULTANEOUSLY TO SEND A LOCK SIGNAL. TURN IGNITION TO OFF. THE LOCKS WILL
CYCLE AGAIN TO INDICATE THE END OF THE PROGRAMMING MODE.
5. The keypad will normally illuminate for 5 seconds after one or more buttons are pressed, and the
illumination will immediately turn off if the 7-8 and 9-0 buttons are pressed simultaneously (lock all
doors). The keypad contains an optical sensor and will not illuminate under bright lighting
conditions. The keypad may only illuminate briefly in colder temperatures in order to maximize the
battery power available to transmit a lock/unlock signal. The temperature at which this occurs will
vary depending upon the keypad battery age and condition. Both of these conditions are a normal
function of the Power Save Mode and do not indicate a need to replace the keypad.
6. After entering the keypad code, the system may unlock the driver's door, lock it, then unlock it
again, and the keypad will not even briefly illuminate. This is the Alert Mode and is an indication
that battery power is very low and the keypad must be replaced.
7. The keypad also contains an Anti-scan feature. If the wrong code has been entered 7 times (35
consecutive button presses) the keypad is disabled for one minute and the keypad lamp will flash
during this time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Keyless Entry - Keypad Diagnostics > Page 10283
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
DEALER CODING
CONDITION
BASIC PART NO. CODE
14A626 42
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 10284
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 10285
Keyless Entry Key-Pad: Service Precautions
CAUTION: Do not operate the radio chassis with a radio speaker disconnected.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 10286
Keyless Entry Key-Pad: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the front door trim panel.
CAUTION: Do not operate the radio chassis with a radio speaker disconnected.
3. Remove the screws and lift the radio speaker out to gain access to the electrical connector.
4. Disconnect the speaker wiring connector.
5. Disconnect the electrical connector.
- Release harness pin-type retainers.
6. Remove the keyless entry keypad and harness.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information >
Technical Service Bulletins > Page 10287
1 Remove the clip.
2 Remove the keyless entry keypad and harness.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km)
or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10293
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10294
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10295
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10296
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10297
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10298
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10299
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10300
Keyless Entry Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10301
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10302
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10303
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10304
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10305
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 10306
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Page 10307
Keyless Entry Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Page 10308
Keyless Entry Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Diagrams > Page 10309
Keyless Entry Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Locations
Door Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Actuator
Power Door Lock Actuator: Service and Repair Front Door Actuator
Heavy Duty Riveter
SPECIAL SERVICE TOOLS
REMOVAL
1. Remove the front door trim panel. 2. Remove the watershield
3. Remove the power door lock actuator.
1 Disconnect the electrical connector.
2 Drill out the rivet.
3 Disconnect the actuator rod.
4 Remove the actuator.
INSTALLATION
1. To install, reverse the removal procedure.
- Use Heavy-Duty Riveter to install the actuator rivet.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Front Door Actuator > Page 10316
Power Door Lock Actuator: Service and Repair Rear Door Actuator
Heavy Duty Riveter
SPECIAL SERVICE TOOLS
REMOVAL
1. Remove the rear door trim panel.
2. Remove the rear door watershield.
3. Remove the power door lock actuator.
1 Disconnect the electrical connector.
2 Drill out the rivet.
3 Disconnect the actuator rod.
4 Remove the actuator.
INSTALLATION
1. To install, reverse the removal procedure.
- Use Heavy-Duty Riveter to install the actuator rivet.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information
> Service and Repair > Page 10317
Heavy Duty Riveter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Locations > Page 10321
Power Door Lock Control Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Locations > Page 10322
Power Door Lock Control Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Control Module > Component
Information > Locations > Page 10323
Power Door Lock Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Locations
Power Door Lock Relay: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Locations > Page 10327
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Locations > Page 10328
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Testing and Inspection > Two Door Models
Power Door Lock Relay: Testing and Inspection Two Door Models
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Testing and Inspection > Two Door Models > Page 10331
Power Door Lock Relay: Testing and Inspection Four Door Models
Driver Door Unlock Relay
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information >
Testing and Inspection > Two Door Models > Page 10332
Door Lock/Unlock Relays
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Master Window/Door Lock Control Switch
4 Door
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Diagrams > Master Window/Door Lock Control Switch > Page 10337
Power Door Lock Switch: Diagrams Power Door Lock Switch
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Left Front
Power Door Lock Switch: Testing and Inspection Left Front
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Left Front > Page 10340
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Left Front > Page 10341
Power Door Lock Switch: Testing and Inspection Right Front
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information >
Testing and Inspection > Left Front > Page 10342
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information >
Specifications
Trunk / Liftgate Lock Cylinder: Specifications
Liftgate Lock Cylinder Nuts 6-7 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information >
Specifications > Page 10346
Liftgate Latch Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information >
Specifications > Page 10347
Trunk / Liftgate Lock Cylinder: Service and Repair
REMOVAL
NOTE: Individual lock cylinders are repaired by discarding the inoperative cylinder and building a
new lock cylinder using the appropriate lock repair package. The lock repair package includes a
detailed instruction sheet to build the new lock cylinder to the current key code of the vehicle.
1. If equipped, remove the liftgate lock actuator. For additional information, refer to Liftgate Lock
Actuator. 2. Remove the liftgate latch remote control. For additional information, refer to Liftgate
Latch.
3. Remove the liftgate lock cylinder.
1 Remove the nuts.
2 Remove the liftgate lock cylinder. If equipped, disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: Manually close the liftgate window latch to set the latch control rod length.
- Make sure the liftgate window latch actuating rod is not preloading the liftgate window latch. It
should be clipped in a relaxed state with no slack.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch > Component
Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
10356
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
10357
Power Mirror Switch: Testing and Inspection
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page
10358
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Premature Clearcoat Cracking Service Tips
Paint: Technical Service Bulletins Paint - Premature Clearcoat Cracking Service Tips
Article No. 02-17-1
PAINT-PREMATURE CLEARCOAT CRACKING-SERVICE TIPS
FORD: 1999-2002 EXPLORER
2000-2002 EXPLORER SPORT TRAC, EXPLORER SPORT
MERCURY: 1999-2002 MOUNTAINEER
ISSUE
Some vehicles may exhibit crowsfoot or premature star cracking primarily on the hood, but could
also be on other panels. This is due to high paint film build and acrylic melamine paint technology.
ACTION
Read this TSB in its entirety BEFORE beginning any repairs. Inspect and repair as outlined in
following Service Procedures.
SERVICE PROCEDURE
1999-2002 Vehicles-Dark Colors (Code LL Blue, Code UA Black, and Code SU Green only)
NOTE READ THIS REPAIR PROCEDURE COMPLETELY. SUBJECT VEHICLES HAVE PAINT
THICKNESS ABOVE 5.5 MILS.
1. Check paint film thickness on affected panels.
NOTE IF PLASTIC MEDIA BLASTING IS BEING USED, PROCEED TO STEP 4.
NOTE TECHNICIAN PERFORMING THE SANDING OPERATION SHOULD WEAR AN
APPROVED RESPIRATOR WITH HIGH EFFICIENCY PARTICULATE FILTERS (HEPA).
TECHNICIANS SHOULD USE A DUAL ACTION SANDER WITH VACUUM COLLECTION
EQUIPMENT. THE VACUUM EQUIPMENT MUST BE EQUIPPED WITH A HEPA FILTER ON
THE AIR EXHAUST. OPERATORS ARE CAUTIONED TO FOLLOW MANUFACTURERS
GUIDELINES FOR MAINTENANCE OR REPLACEMENT OF THESE FILTERS.
2. Remove all clearcoat and basecoat by sanding down to the E-coat primer with 80 grit-sanding
discs on a Dual Action vacuum sander. The E-coat
color is Green.
3. Blow off the panel with compressed air to remove loose dust and debris. 4. Wipe the panel with
a wax and grease remover. Wipe dry using a clean, lint-free cloth to remove all residue. Keep
wiping until the surface is
completely dry.
5. Mask off all necessary panels. Tack off the surface. 6. Mix and apply Ford Approved epoxy or
self-etching primer to all bare metal areas on the panel. 7. Mix and apply 2.0 mils minimum of Ford
Approved primer surfacer following the manufacturers label recommendations and bake at 140°F
(60°
C) panel temperature per manufacturers recommended baking time.
8. Block sand the affected panels with 600 grit sand paper. 9. Blow off the area with compressed
air to remove loose dust and debris.
10. Wipe the panel with a wax and grease remover. Wipe dry using a clean, lint-free cloth to
remove all residue.
NOTE KEEP WIPING UNTIL THE SURFACE IS COMPLETELY DRY. ANY RESIDUE MAY
RESULT CONTAMINATION OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP.
11. Mix and apply Ford Approved basecoat material following the manufacturers label
recommendations and flash time. 12. Mix and apply 2.0 mils minimum of Ford Approved clearcoat
and bake at 140°F (60°C) panel temperature per manufacturers recommended
baking time.
13. Demask the vehicle as necessary.
WARNING TO SAFEGUARD OUR ENVIRONMENT, PLEASE USE PROPER DISPOSAL
TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (VOC) OR EXCESS MATERIALS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service
Bulletins > Paint - Premature Clearcoat Cracking Service Tips > Page 10364
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS
CODES: 106000
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes
Paint: Application and ID Paint Codes
IDENTIFICATION CODES
The Vehicle Identification Number (VIN) is a seventeen-digit combination of letters and numbers.
The VIN is stamped on a metal tab riveted on the instrument panel, top upper left of the dash. The
VIN number is also found on the Vehicle Certification (VC) label.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 10367
VEHICLE CERTIFICATION LABEL CODES
The Vehicle Certification (VC) label contains the manufacturer name, the month and year of
manufacture, the certification statement, and the VIN. It also includes Gross Vehicle Weight
Ratings (GVWR).
The following lists the exterior paint codes: Primary body color codes B2 - Harvest Gold
- B4 - Autumn Brown
- FL - Medium-Toreador Red
- FS - Spruce Green
- LD - Medium Wedgewood Blue
- LL - Deep Wedgewood Blue
- SU - Amazon Green
- UA - Ebony
- WF - White Pearl, tri-coat (St. Louis build only)
- YZ - Oxford White
Lower two-tone exterior paint codes: RC - Medium Platinum
- BA - Medium Prairie Tan (Mountaineer Appearance Package)
- JL - Dark Toreador Red
- LD - Medium Wedgewood Blue
- ST - Estate Green
Tape Stripe Codes
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 10368
- L - Light Prairie Tan (Limited)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID
> Paint Codes > Page 10369
Paint: Application and ID Paint Code Sticker Location
VEHICLE CERTIFICATION LABEL REFERENCE
The VC label is located on the left-hand front door or door jamb and is in a similar location on
trucks.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions
Keyless Entry Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10376
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10377
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10378
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10379
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10380
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10381
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10382
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10383
Keyless Entry Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10384
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10385
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10386
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10387
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10388
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 10389
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 10390
Keyless Entry Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 10391
Keyless Entry Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Diagrams > Page 10392
Keyless Entry Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Locations > Page 10396
Power Door Lock Control Module: Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Locations > Page 10397
Power Door Lock Control Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Control Module >
Component Information > Locations > Page 10398
Power Door Lock Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Power Door Lock Relay: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 10402
4 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations > Page 10403
2 Door W/Electronics Group
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Testing and Inspection > Two Door Models
Power Door Lock Relay: Testing and Inspection Two Door Models
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Testing and Inspection > Two Door Models > Page 10406
Power Door Lock Relay: Testing and Inspection Four Door Models
Driver Door Unlock Relay
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Testing and Inspection > Two Door Models > Page 10407
Door Lock/Unlock Relays
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams
Power Seat Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Diagrams > Page 10411
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Service Precautions > Technician Safety Information
Power Seat Control Module: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Service Precautions > Technician Safety Information > Page 10414
Power Seat Control Module: Vehicle Damage Warnings
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Service Precautions > Page 10415
Power Seat Control Module: Service and Repair
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track,
Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Remove the Driver Seat Module (DSM).
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the DSM.
INSTALLATION
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Service Precautions > Page 10416
1. Install the DSM.
1 Connect the electrical connectors.
2 Position the DSM.
3 Install the screws.
2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the
restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Left > Page 10421
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Page 10422
Seat Heater Control Module: Service and Repair
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track,
Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Disconnect the heated seat module electrical connector.
4. Remove the heated seat module.
1 Release the clip.
2 Remove the heated seat module.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Diagrams > Page 10423
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
1. Install the heated seat module.
2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For
additional information, refer to Seat-Track, Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the
restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Specifications
Sunroof / Moonroof Motor: Specifications
Roof Opening Panel Motor Bolts 5 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Specifications > Page 10429
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Motor > Component Information > Specifications > Page 10430
Sunroof / Moonroof Motor: Service and Repair
REMOVAL
1. Remove the overhead console. For additional information, refer to Interior Trim.
2. Remove the motor.
1 Remove the bolts.
2 Disconnect the electrical connector.
NOTE: Make sure that the roof opening panel motor is in the closed position before removal.
INSTALLATION
1. Connect the roof opening panel motor electrical connector.
NOTE: The roof opening panel should be in the closed position.
2. Position the overhead console and connect the electrical connectors. 3. With the motor still
removed, bump the switch one time only towards the close or vent open position.
4. Position the roof opening panel motor and install the bolts. 5. Install the overhead console. For
additional information, refer to Interior Trim.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Switch > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Air Deflector
Sunroof / Moonroof Windguard: Service and Repair Air Deflector
REMOVAL
1. Open the roof opening panel to the fully retracted position.
2. Release the two air deflector arms.
3. Remove the air deflector.
1 Detach the two air deflector retainer clips from the U-frame.
2 Remove the air deflector.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Air Deflector > Page 10438
Sunroof / Moonroof Windguard: Service and Repair Roof Opening Panel Shield
REMOVAL
1. Remove the roof opening panel.
2. Remove the water channel.
1 Remove the screws.
2 Remove the water channel.
3. Slide the roof opening panel shield forward halfway.
4. Disengage the roof opening panel shield spring loaded guide feet.
1 Push the roof opening panel shield toward one side of the vehicle.
2 Lift the front portion of the roof opening panel shield upward to disengage the spring loaded guide
feet.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Windguard > Component Information > Service and Repair > Air Deflector > Page 10439
5. Slide the roof opening panel shield forward and release the rear guide feet.
INSTALLATION
6. To install, reverse the removal procedure.
NOTE: When installing the water channel, make sure that the water channel is seated on the
locking clips. The LH water channel screw must be installed first.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Drain > Component Information > Service and Repair
Sunroof / Moonroof Drain: Service and Repair
REMOVAL
1. Remove the headliner.
2. From underneath the vehicle, securely attach a new drain hose to the lower end of the old drain
hose.
3. Disconnect the drain hose from the roof opening panel assembly.
4. Pull the old drain hose through the body of the vehicle and connect the new hose to the roof
opening panel.
NOTE: Make sure that the hoses are not kinked.
INSTALLATION
1. Install the headliner.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof /
Moonroof Frame > Component Information > Service and Repair
Sunroof / Moonroof Frame: Service and Repair
REMOVAL
1. Remove the headliner.
2. Disconnect the roof opening panel motor electrical connector.
3. Remove the roof opening panel frame.
1 Disconnect the four drain hoses.
2 Remove the fourteen screws.
3 Remove the roof opening panel frame.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams
Power Seat Control Module: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Diagrams >
Page 10454
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service
Precautions > Technician Safety Information
Power Seat Control Module: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service
Precautions > Technician Safety Information > Page 10457
Power Seat Control Module: Vehicle Damage Warnings
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service
Precautions > Page 10458
Power Seat Control Module: Service and Repair
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the seat track assembly. For additional information, refer to Seat-Track,
Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Remove the Driver Seat Module (DSM).
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the DSM.
INSTALLATION
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Service
Precautions > Page 10459
1. Install the DSM.
1 Connect the electrical connectors.
2 Position the DSM.
3 Install the screws.
2. Install the seat track. For additional information, refer to Seat-Track, Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
4. Prove out the air bag system. For additional information, refer to Air Bag Systems. 5. Check the
restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Left
Power Seat Motor: Diagrams Left
W/O Memory Seats
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Page 10464
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Page 10465
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Diagrams > Left
Power Seat Switch: Diagrams Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Page 10470
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Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions
> Technician Safety Information
Power Seat Switch: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service Precautions
> Technician Safety Information > Page 10473
Power Seat Switch: Vehicle Damage Warnings
CAUTION:
- To prevent damage to the side shield, the clips must be depressed in order to release the side
shield from the cushion pan.
- Use care when disconnecting the seat cushion side shield from the seat cushion frame so the
tabs on the seat cushion side shield are not damaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Seat Memory Set Switch
Power Seat Switch: Testing and Inspection Seat Memory Set Switch
Remove the memory set switch. Measure the resistance between the indicated terminals while
pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the
calling Pinpoint Test.
To check the memory set switch LED, connect the positive meter lead to terminal 8 and the
negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads,
the meter should read OL.
If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling
Pinpoint Test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Testing and
Inspection > Seat Memory Set Switch > Page 10476
Power Seat Switch: Testing and Inspection Seat Regulator Control Switch
Remove the seat regulator control switch. Measure the resistance between the indicated terminals
while pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the
calling Pinpoint Test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Sport Bucket
Power Seat Switch: Service and Repair Sport Bucket
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket,
3. Remove the lumbar support knob.
4. Remove the rear side shield screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Sport Bucket > Page 10479
5. Release the side shield clips.
CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release
the side shield from the cushion pan.
6. Unhook the side shield from the seat latch.
7. If equipped, disconnect the heated seat switch electrical connector.
8. Remove the side shield.
1 Disconnect the electrical connector.
2 Remove the side shield.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Sport Bucket > Page 10480
9. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For
additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional
information, refer to Air Bag Systems. 4. Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Sport Bucket > Page 10481
Power Seat Switch: Service and Repair Limited
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Sport Bucket > Page 10482
5. Remove the front seat cushion side shield screws.
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Disconnect the lumbar support control switch electrical connector.
8. Disconnect the lumbar support adjusting hoses from the adjusting switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair >
Sport Bucket > Page 10483
9. If equipped, disconnect the heated seat switch electrical connector.
10. Remove the front seat cushion side shield.
11. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect
Technical Service Bulletin # 03S04S1 Date: 060401
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10493
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006.
FSA VIN LIST ACTIVATED? Yes
Available through the website by April 5, 2006.
Owner names and addresses will be available for the additional vehicles by April 17, 2006.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
Related damage claims are not approved for this program.
ADDITIONAL LABOR TIME
This repair will require no additional labor time to complete. Claims submitted with "MT" labor will
not be accepted for reimbursement.
OWNER REFUNDS
^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair
was performed prior to the date indicated in the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10494
reimbursement plan, which is posted with this bulletin. This plan is also available to owners through
the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement
through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box
6251, Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund
claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be
accepted for reimbursement.
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the vehicle.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 03S04 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refund or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires approval from Special Service Support
Center.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will
only be used on approximately 25% of the repairs.
The DOR/COR for this program is 50309. This number identifies parts ordered for this recall
through the Special Service Support Center.
RECALL PARTS SUPPORT CENTER
The Recall Parts Support Center can be contacted via:
^ Phone
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Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10495
^ E-mail
^ FAX
Please be prepared to provide the following information:
^ Dealer Name and P & A code
^ Contact Name
^ Phone number and E-mail address
^ FSA #: 03804
^ Vehicle Identification Number (if requested)
DEALER PRICE
For latest prices1 refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures".
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW
This procedure involves replacement of certain seat recliner assembly attaching hardware on two
different style driver seat assemblies. The driver seat will have either a stamped seat back frame or
a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the
seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2.
^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner
mechanism attaches to the seatback frame. See Figure 1.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10496
^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is
evident on the tubular seatback frame. See Figure 2.
For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure
3.
^ Stamped Seatback - The kit consists of:
- One (1) UPPER bolt with thread sealer patch (bolt A)
- One (1)1-inch spacer (spacer A)
^ Tubular Seatback - The kit consists of:
- One (1) UPPER bolt with thread sealer patch (bolt A)
- One (1) LOWER bolt without thread sealer patch (bolt B)
- One (1) 3/4-inch spacer (spacer B)
SERVICE PROCEDURE
FOR ALL AFFECTED VEHICLES
WARNING:
ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL
RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
WARNING:
TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER
DEVICES.
NOTE:
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Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10497
If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is
being serviced, the supplemental restraint system (SRS) must be depowered.
1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim
and accessories may vary from one seat to another of the same frame configuration.
Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover
and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back
frame.
2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio
stations.
3. Position the driver seat to its full-forward position.
4. Turn the ignition switch from RUN to OFF.
5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge
area and then remove the applicable airbag fuse. Refer to the following chart to determine which
fuse must be removed when working on a vehicle with side air bags.
6. Disconnect the battery negative cable and wait one minute.
7. Position the driver seatback to Its full4orward position.
8. CAUTION: Take care not to damage the seatback trim cover during this step.
Unhook the seatback trim cover J-clip. See Figure 4.
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9. Position the driver seatback to a straight-up position. See Figure 5.
10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See
Figure 6.
11. Remove and discard the upper bolt.
12. Remove and discard the plastic bushing. See Figure 7.
13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3.
^ Spacer A 1-inch on STAMPED seatback frames.
^ Spacer B 3/4-Inch on TUBULAR seatback frames.
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Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10499
Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer
should be between the recliner mechanism arm and the seatback frame. See Figure 8.
14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft).
15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original
position.
16. Position the driver seatback to its full4orward position.
17. Connect the seatback trim cover J-clip.
18. Position the driver seatback to its original position.
^ If the vehicle is equipped with a tubular seatback frame, go to Step 23.
^ If the vehicle is equipped with a stamped seatback frame, continue with the next step.
19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the
ignition switch from OFF to RUN.
20. Install the airbag fuse and then install the fuse box cover.
21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING
BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE
CABLE IS CONNECTED.
Connect the battery negative cable.
22. Position the driver seat to its original position and program the recorded preset radio stations.
THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK
FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS.
23. Position the seat cushion side shield aside as follows:
^ Pull off the lumbar support manual adjuster knob, if equipped.
^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment).
^ GENTLY unsnap the shield from the seat frame and position the shield out of the way.
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24. Remove and discard the lower bolt from the recliner assembly. See Figure 9.
25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft).
26. Install the seat cushion side shield as follows:
^ Align and snap the shield into place.
^ Install the two (2) removed screws.
^ Install the lumbar support adjuster knob.
27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the
ignition switch from OFF to RUN.
28. Install the airbag fuse and then install the fuse box cover.
29.
WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING
BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE
CABLE IS CONNECTED.
Connect the battery negative cable.
30. Position the driver seat to its original position and program the recorded preset radio stations.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10501
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Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10502
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > Recalls for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat Recliner Bolt Defect > Page
10503
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect
Technical Service Bulletin # 03S04S1 Date: 060401
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10509
Attachment I - Administrative Information
OASIS ACTIVATED? Yes. OASIS will be activated for the additional vehicles by April 3, 2006.
FSA VIN LIST ACTIVATED? Yes
Available through the website by April 5, 2006.
Owner names and addresses will be available for the additional vehicles by April 17, 2006.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your new vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the owner a copy of the Customer Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
RELATED DAMAGE
Related damage claims are not approved for this program.
ADDITIONAL LABOR TIME
This repair will require no additional labor time to complete. Claims submitted with "MT" labor will
not be accepted for reimbursement.
OWNER REFUNDS
^ Ford Motor Company is offering a refund for owner-paid repairs covered by this recall if the repair
was performed prior to the date indicated in the
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Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10510
reimbursement plan, which is posted with this bulletin. This plan is also available to owners through
the Customer Relationship Center (CRC). The CRC will direct owners to seek reimbursement
through authorized dealers or1 at their option, directly through Ford Motor Company at P.O. Box
6251, Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner-paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan. Refund
claims that include other non-covered repairs, or those judged by Ford to be excessive, will not be
accepted for reimbursement.
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the vehicle.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 03S04 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refund or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires approval from Special Service Support
Center.
^ Refer to ACESII manual for claims preparation and submission information.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Please be aware the BB kit will be utilized on approximately 75% of all repairs while the CA kit will
only be used on approximately 25% of the repairs.
The DOR/COR for this program is 50309. This number identifies parts ordered for this recall
through the Special Service Support Center.
RECALL PARTS SUPPORT CENTER
The Recall Parts Support Center can be contacted via:
^ Phone
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Ford Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10511
^ E-mail
^ FAX
Please be prepared to provide the following information:
^ Dealer Name and P & A code
^ Contact Name
^ Phone number and E-mail address
^ FSA #: 03804
^ Vehicle Identification Number (if requested)
DEALER PRICE
For latest prices1 refer to DOES II.
PARTS RETENTION AND RETURN
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures".
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
OVERVIEW
This procedure involves replacement of certain seat recliner assembly attaching hardware on two
different style driver seat assemblies. The driver seat will have either a stamped seat back frame or
a tubular seat back frame. These seats can be distinguished from one another by slightly lifting the
seat back cover and viewing the corner of the seat back frame itself. See Figures 1 and 2.
^ Tubular seatback frames can be identified by a hole in the lower flange where the recliner
mechanism attaches to the seatback frame. See Figure 1.
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Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10512
^ Stamped seatback frames can be identified by not having the tell-tale hole in the frame that is
evident on the tubular seatback frame. See Figure 2.
For each type of seat, a different service kit is required. Kits are NOT interchangeable. See Figure
3.
^ Stamped Seatback - The kit consists of:
- One (1) UPPER bolt with thread sealer patch (bolt A)
- One (1)1-inch spacer (spacer A)
^ Tubular Seatback - The kit consists of:
- One (1) UPPER bolt with thread sealer patch (bolt A)
- One (1) LOWER bolt without thread sealer patch (bolt B)
- One (1) 3/4-inch spacer (spacer B)
SERVICE PROCEDURE
FOR ALL AFFECTED VEHICLES
WARNING:
ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIRBAG SUPPLEMENTAL
RESTRAINT SYSTEM VEHICLE AND WHEN WORKING NEAR AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF PERSONAL INJURY IN THE EVENT OF AN ACCIDENTAL
DEPLOYMENT.
WARNING:
TO REDUCE THE RISK OF PERSONAL INJURY, DO NOT USE ANY MEMORY SAVER
DEVICES.
NOTE:
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Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10513
If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner system is
being serviced, the supplemental restraint system (SRS) must be depowered.
1. NOTE: Only use the method described to distinguish between driver seatback frame types. Trim
and accessories may vary from one seat to another of the same frame configuration.
Identify the type of seat back frame by slightly lifting the outside rear corner of the seat back cover
and viewing the frame itself. Be sure to procure the proper kit based on the type of seat back
frame.
2. NOTE: Go to Step 7 if the vehicle is not equipped with side air bags. Record the preset radio
stations.
3. Position the driver seat to its full-forward position.
4. Turn the ignition switch from RUN to OFF.
5. Remove the fuse box cover from the left side of the instrument panel near the driver door hinge
area and then remove the applicable airbag fuse. Refer to the following chart to determine which
fuse must be removed when working on a vehicle with side air bags.
6. Disconnect the battery negative cable and wait one minute.
7. Position the driver seatback to Its full4orward position.
8. CAUTION: Take care not to damage the seatback trim cover during this step.
Unhook the seatback trim cover J-clip. See Figure 4.
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Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10514
9. Position the driver seatback to a straight-up position. See Figure 5.
10. Carefully pull the outside of the seatback trim cover up to expose the recliner upper bolt. See
Figure 6.
11. Remove and discard the upper bolt.
12. Remove and discard the plastic bushing. See Figure 7.
13. CAUTION: Be sure to use the correct spacer for the application. Refer to Figure 3.
^ Spacer A 1-inch on STAMPED seatback frames.
^ Spacer B 3/4-Inch on TUBULAR seatback frames.
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Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10515
Insert the new spacer from the inboard side of the bolt hole. When Inserted correctly, the spacer
should be between the recliner mechanism arm and the seatback frame. See Figure 8.
14. Install the new upper bolt (Bolt A). Tighten the bolt to 45 Nm (33 lb-ft).
15. Carefully install the seatback trim cover over the recliner mechanism arm and into its original
position.
16. Position the driver seatback to its full4orward position.
17. Connect the seatback trim cover J-clip.
18. Position the driver seatback to its original position.
^ If the vehicle is equipped with a tubular seatback frame, go to Step 23.
^ If the vehicle is equipped with a stamped seatback frame, continue with the next step.
19. NOTE: If the vehicle is not equipped with side air bags, no further service Is required. Turn the
ignition switch from OFF to RUN.
20. Install the airbag fuse and then install the fuse box cover.
21. WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING
BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE
CABLE IS CONNECTED.
Connect the battery negative cable.
22. Position the driver seat to its original position and program the recorded preset radio stations.
THIS COMPLETES SERVICE ON STAMPED SEATBACK FRAMES. FOR TUBULAR SEATBACK
FRAMES, PLEASE CONTINUE WITH THE FOLLOWING STEPS.
23. Position the seat cushion side shield aside as follows:
^ Pull off the lumbar support manual adjuster knob, if equipped.
^ Remove two (2) shield attaching screws (three [3] If equipped with power lumbar adjustment).
^ GENTLY unsnap the shield from the seat frame and position the shield out of the way.
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Recliner Bolt Defect > Page 10516
24. Remove and discard the lower bolt from the recliner assembly. See Figure 9.
25. Install the new lower bolt (Bolt B) into the recliner assembly. Tighten the bolt to 45 Nm (33 lb-ft).
26. Install the seat cushion side shield as follows:
^ Align and snap the shield into place.
^ Install the two (2) removed screws.
^ Install the lumbar support adjuster knob.
27. NOTE: If the vehicle is not equipped with side air bags, no further service is required. Turn the
ignition switch from OFF to RUN.
28. Install the airbag fuse and then install the fuse box cover.
29.
WARNING: BE SURE THAT NOBODY IS IN THE VEHICLE AND THAT THERE IS NOTHING
BLOCKING OR SET IN FRONT OF ANY AIRBAG MODULE WHEN THE BATTERY NEGATIVE
CABLE IS CONNECTED.
Connect the battery negative cable.
30. Position the driver seat to its original position and program the recorded preset radio stations.
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Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10517
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Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10518
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Service Bulletins > All Technical Service Bulletins for Seat Back Frame: > 03S04S1 > Apr > 06 > Recall - Driver Seat
Recliner Bolt Defect > Page 10519
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Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service Precautions >
Technician Safety Information
Seat Cushion: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
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Technician Safety Information > Page 10524
Seat Cushion: Vehicle Damage Warnings
CAUTION:
- The flex mat J-clips must be installed with the openings facing down or the seat cushion will be
damaged.
- Use care when separating the seat cushion trim cover from the hook and loop strip or the hook
and loop strip may be torn from the seat cushion foam.
- Any time the seat cushion heating element is removed from the seat cushion foam, the foam must
be replaced.
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Portion of Rear 60/40 Split Bench
Seat Cushion: Service and Repair 40% Portion of Rear 60/40 Split Bench
DISASSEMBLY
1. Disassemble the rear 40 percent seat. For additional information, refer to Seat-Rear, 60%
Portion of 60/40 Split Bench.
2. Remove the rear seat legs.
1. Remove the pivot bolts. 2. Remove the rear seat legs.
3. Unhook the seat cushion trim cover J-clips.
4. Remove the seat cushion trim cover.
- Separate the seat cushion trim cover from the hook and loop strip.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
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5. Remove the seat cushion flex mat.
1. Unhook the rear flex mat J-clip. 2. Unhook the front flex mat J-clip. 3. Remove the seat cushion
flex mat.
NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the
rear flex mat J-clip.
ASSEMBLY
1. Install the seat cushion flex mat.
1. Position the seat cushion flex mat. 2. Hook the front flex mat J-clip. 3. Hook the rear flex mat
J-clip.
CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion
will be damaged.
NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the
rear flex mat J-clip.
2. Position the seat cushion trim cover on the seat cushion hook and loop strips.
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3. Hook the seat cushion trim cover J-clips.
4. Install the rear seat riser pivot bolts.
1. Position the rear seat legs. 2. Install the rear seat riser pivot bolts.
5. Assemble the rear 40 percent seat. For additional information, refer to Seat-Rear, 60% Portion of
60/40 Split Bench.
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Seat Cushion: Service and Repair 60% Portion of Front 60/40 Split Bench
DISASSEMBLY
1. Disassemble the seat. For additional information, refer to Seat-60% Portion of Front 60/40 Split
Bench.
2. Unhook the seat cushion trim cover J-clips.
3. Remove the seat cushion frame from the seat cushion foam. 4. Invert the seat cushion trim
cover.
5. Remove the seat cushion trim cover. Separate the seat cushion trim cover from the hook and
loop strip.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
ASSEMBLY
1. To assemble, reverse the disassembly procedure.
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Seat Cushion: Service and Repair 60% Portion of Rear 60/40 Split Bench
DISASSEMBLY
1. Disassemble the 60 percent rear seat. For additional information, refer to Seat-Rear, 60%
Portion of 60/40 Split Bench.
2. Remove the seat cushion legs.
1. Remove the pivot bolts. 2. Remove the seat cushion legs.
3. Remove the seat cushion frame from the seat cushion foam.
1. Unhook the seat cushion trim cover J-clips. 2. Remove the seat cushion frame from the seat
cushion foam.
4. Invert the seat cushion trim cover.
5. Remove the seat cushion trim cover.
- Separate the seat cushion trim cover from the hook and loop strip.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
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Portion of Rear 60/40 Split Bench > Page 10531
6. Remove the seat cushion flex mats.
1. Unhook the rear flex mat J-clips. 2. Unhook the front flex mat J-clips. 3. Remove the seat
cushion flex mats.
NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to unhook the
rear flex mat J-clip.
ASSEMBLY
1. Install the seat cushion flex mats.
1. Position the seat cushion flex mats. 2. Hook the front flex mat J-clips. 3. Hook the rear flex mat
J-clips.
CAUTION: The flex mat J-clips must be installed with the openings facing down or the seat cushion
foam will be damaged.
NOTE: Use the brackets on the seat cushion frame to obtain the necessary leverage to hook the
rear flex mat clip.
2. Position the seat cushion trim cover on the seat cushion hook and loop strips.
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3. Install the seat cushion frame into the seat cushion foam.
1. Position the seat cushion frame. 2. Hook the seat cushion trim cover J-clips.
4. Install the seat cushion legs.
1. Position the seat cushion legs. 2. Install the rear seat riser pivot bolts.
5. Assemble the 60 percent rear seat. For additional information, refer to Seat-Rear, 60% Portion of
60/40 Split Bench.
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Seat Cushion: Service and Repair Front Bucket
6-Way Power, Except Limited
DISASSEMBLY
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
- Before disconnecting the battery, raise the seat to the highest position, then move and tilt the seat
to its most forward position.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Disassemble the 6-way power front bucket seat. For additional information, refer to
Seat-Front Bucket, 6-Way Power, Except limited.
NOTE : Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6Way Power, Except
Limited, Disassembly and Assembly.
3. Disconnect the seat cushion trim cover J-clips.
4. If equipped, disconnect the seat cushion heating element electrical connector.
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5. Remove the seat cushion frame from the seat cushion foam. 6. Invert the seat cushion trim
cover.
7. Remove the swing rods.
1 Remove and discard the hog rings.
2 Remove the swing rods.
8. Remove the seat cushion trim cover.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
9. If equipped, and if necessary, remove the seat cushion heating element from the seat cushion
foam.
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CAUTION: Any time the seat cushion heating element is removed from the seat cushion foam, the
foam must be replaced.
10. Remove the wire harness from the scat cushion frame.
ASSEMBLY
1. Install the wire harness.
2. If equipped, and if necessary, install the seat cushion heating element.
3. Position the seat cushion trim cover.
NOTE: When installing a new seat cushion trim cover, it may be necessary to cut a hole for the
front seat back pad adjusting cable, backrest heating element electrical lead, and the side air bag
wiring harness. Use the old seat cushion trim cover as a guide for the location of the hole.
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4. Install the seat cushion swing rods.
1 Position the swing rods.
NOTE: Make sure the ends of the swing rods are positioned beneath the listing wires at the rear of
the seat cushion foam.
2 Install the hog rings.
5. Invert the seat cushion trim cover.
6. Connect the seat cushion trim cover J-clips. 7. Assemble the 6-way power front bucket seat. For
additional information, refer to Seat-Front Bucket, 6-Way Power, Except Limited.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, 6-Way Power, Except
Limited, Disassembly and Assembly.
8. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
9. Prove out the air bag system. For additional information, refer to Air Bag Systems. 10. Check the
restraint system for proper operation.
Limited
DISASSEMBLY
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
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- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
- Before disconnecting the battery, raise the seat to the highest position, then move and tilt the seat
to its most forward position.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Disassemble the seat. For additional information, refer to Seat-Front Bucket, Limited.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, Limited, Disassembly
and Assembly.
3. Disconnect the seat backrest recliner actuator.
1 Remove the screws.
2 Disconnect the seat backrest recliner actuator.
4. If equipped, disconnect the seat cushion heating element electrical connector.
5. Remove the seat cushion frame from the seat cushion foam.
1 Unhook the seat cushion trim cover J-clips.
2 Remove the seat cushion frame from the seat cushion foam.
6. Invert the seat cushion trim cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10538
7. Remove and discard the hog rings.
1 Fold back the seat cushion trim cover to expose the hog rings.
2 Remove and discard the hog rings.
NOTE: The hog rings along the front of the seat are shown, the hog rings along either side are
similar.
8. If equipped, and if necessary, remove the seat cushion heating element from the seat cushion
foam.
CAUTION: Any time the seat cushion heating element is removed from the seat cushion foam, the
foam must be replaced.
NOTE: Sport bucket seat shown; Limited seat similar.
9. Disconnect the heated seat module electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10539
10. Remove the heated seat module.
1 Release the clip.
2 Remove the heated seat module.
11. Remove the driver seat module (DSM).
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the DSM.
12. Disconnect the lumbar support adjusting pump electrical connector.
13. Remove the power seat wiring harness.
1 Disconnect the pin-type retainers.
2 Remove the power seat wiring harness.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10540
14. Remove the flexilator.
1 Remove the flexilator springs.
2 Remove the flexilator.
15. Remove the lumbar support adjusting pump.
1 Remove the bolt.
2 Remove the lumbar support adjusting pump.
16. Remove the seat backrest recliner roll pins and remove the seat backrest recliners.
17. Disconnect the seat backrest recliners from the seat backrest recliner actuator.
1 Disconnect the seat backrest recliner actuator cable housings from the seat backrest recliners.
2 Unhook the seat backrest recliner actuator cables from the seat backrest recliners.
ASSEMBLY
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10541
1. Connect the seat backrest recliners to the seat backrest recliner actuator.
1 Hook the seat backrest recliner actuator cables to the seat backrest recliners.
2 Connect the seat backrest recliner actuator cable housings to the seat backrest recliners.
2. Install the seat backrest recliner roll pins.
3. Install the lumbar Support adjusting pump.
1 Position the lumbar support adjusting pump.
2 Install the bolt.
4. Install the flexilator.
1 Position the flexilator.
2 Install the flexilator springs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10542
5. Install the power seat wiring harness.
1 Position the power seat wiring harness.
2 Install the pin-type retainers.
6. Connect the lumbar support adjusting pump electrical connector.
7. Install the DSM.
1 Connect the electrical connectors.
2 Position the DSM.
3 Install the screws.
8. Install the hog rings.
1 Fold back the seat cushion trim cover to the hog ring installation position.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10543
2 Install the hog rings.
NOTE: The hog rings along the front of the seat are shown; the hog rings along either side are
similar.
9. Invert the seat cushion trim cover.
10. Install the seat cushion frame.
1 Position the seat cushion frame.
2 Hook the seat cushion trim cover J-clips.
11. If equipped, connect the seat cushion heating element electrical connector.
12. Connect the seat backrest recliner actuator.
1 Connect the seat backrest recliner actuator.
2 Install the screws. Tighten until the screws are fully seated.
13. Assemble the seat. For additional information, refer to Seat-Front Bucket, Limited.
NOTE: Be sure to read and follow all air bag warnings in Seat-Front Bucket, Limited, Disassembly
and Assembly.
14. Reactivate the supplemental restraint system. For additional information, refer to Section Air
Bag Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
15. Prove out the air bag system. For additional information, refer to Air Bag Systems. 16. Check
the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10544
Manual
DISASSEMBLY
1. Disassemble the manual front bucket seat. For additional information, refer to Seat-Front Bucket,
Manual.
2. Disconnect the seat cushion trim cover J-clips.
3. Remove the seat cushion trim cover.
- Disconnect the seat trim cover from the hook and loop strips.
CAUTION: Use care when separating the seat cushion trim cover from the hook and loop strip or
the hook and loop strip may be torn from the seat cushion foam.
4. Remove the seat cushion.
- Disconnect the front and rear J-clips.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10545
5. Remove the flexilator.
1. Remove the flexilator to frame springs. 2. Disengage the spring clip. 3. Disengage the flexilator
hooks from the seat frame. 4. Remove the flexilator.
ASSEMBLY
1. Install the flexilator.
1. Position the flexilator. 2. Install the flexilator hooks to the seat frame. 3. Hook the spring clip. 4.
Install the flexilator to frame springs.
2. Position the seat cushion trim cover on the seat cushion hook and loop strips.
3. Connect the seat cushion trim cover J-clips. 4. Assemble the manual front bucket seat. For
additional information, refer to Seat-Front Bucket, Manual.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10546
Seat Cushion: Service and Repair Rear 50/50 Split Bench
DISASSEMBLY
1. Remove the pivot legs.
1. Remove the bolts. 2. Remove the pivot legs.
2. Remove the seat cushion trim cover.
- Disconnect the pin-type retainers.
3. Remove the seat cushion foam from the seat cushion frame.
ASSEMBLY
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > 40%
Portion of Rear 60/40 Split Bench > Page 10547
1. To assemble, reverse the disassembly procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams >
Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams >
Left > Page 10552
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams >
Page 10553
Seat Heater Control Module: Service and Repair
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the power front seat track. For additional information refer to Seat-Track,
Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
3. Disconnect the heated seat module electrical connector.
4. Remove the heated seat module.
1 Release the clip.
2 Remove the heated seat module.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Diagrams >
Page 10554
CAUTION: Electronic modules are sensitive to static electrical charges. If exposed to these
charges, damage may result.
1. Install the heated seat module.
2. Connect the heated seat module electrical connector. 3. Install the power front seat track. For
additional information, refer to Seat-Track, Limited and 6-Way Power.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Track, Limited and 6-Way
Power, Removal and Installation.
4. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
5. Prove out the air bag system. For additional information, refer to Air Bag Systems. 6. Check the
restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Diagrams > Left >
Page 10559
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Sport Bucket
Seat Heater Switch: Service and Repair Sport Bucket
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Remove the lumbar support knob.
4. Remove the rear side shield screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Sport Bucket > Page 10562
5. Release the side shield clips.
6. Disconnect the heated seat switch electrical connector.
7. Remove the heated seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Sport Bucket > Page 10563
Seat Heater Switch: Service and Repair Limited
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat Systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Sport Bucket > Page 10564
5. Remove the front seat cushion side shield screws.
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Disconnect the lumbar support control switch electrical connector.
8. Disconnect the lumbar support adjusting hoses from the adjusting switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair
> Sport Bucket > Page 10565
9. Disconnect the heated seat switch electrical connector.
10. Remove the front seat cushion side shield.
11. Remove the heated seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front
Manual
Seat Track: Service and Repair Front Manual
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
2. Remove the front seat. For additional information, refer to Seat-Front Bucket, Removal and
Installation.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket.
3. Place the front seat upside-down on a clean workbench.
4. Remove the safety belt buckle slide bar.
1 Remove the nut.
2 Remove the bolt.
3 Remove the safety belt buckle slide bar.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front
Manual > Page 10570
5. Remove the seat track to seat cushion front bolts.
6. Remove the front seat track.
1 Remove the seat track to seat cushion rear bolts.
2 Remove the front seat track.
INSTALLATION
1. Install the front seat track front bolts.
1 Position the front seat track.
2 Install the inboard bolt.
3 Install the outboard bolt.
2. Install the front seat track rear bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front
Manual > Page 10571
1 Install the inboard bolt.
2 Install the outboard bolt.
3. Install the safety belt buckle slide bar.
1 Position the safety belt buckle slide bar.
2 Install the nut.
3 Install the bolt.
4. Install the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
5. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
6. Prove out the air bag system. For additional information, refer to Air Bag Systems. 7. Check the
restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front
Manual > Page 10572
Seat Track: Service and Repair Limited and 6-Way Power
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
CAUTION: Use care when handling the seat and track assembly. Dropping the assembly or sitting
on a seat not secured in the vehicle may result in damaged components.
NOTE:
- LHD seats shown, RHD seat similar.
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Place the seat on a clean workbench.
4. Remove the safety belt buckle slide bar.
1 Remove the nut.
2 Remove the bolt.
3 Remove the safety belt buckle slide bar.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front
Manual > Page 10573
5. Disconnect the seat track wiring hamess electrical connectors.
- If equipped, disconnect the memory seat module electrical connectors.
- Disconnect the seat track motor electrical connectors.
6. Remove the seat track.
1 Remove the bolts.
2 Remove the seat track.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When installing the power seat track, start at the corner with the round hole and work
around the seat base in a horseshoe pattern.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
3. Prove out the air bag system. For additional information, refer to Air Bag Systems.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Service and Repair > Front
Manual > Page 10574
4. Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page
10581
OASIS CODES: 201000, 201200
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Master Window/Door Lock Control Switch
4 Door
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Diagrams > Master Window/Door Lock Control Switch > Page 10586
Power Door Lock Switch: Diagrams Power Door Lock Switch
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Left Front
Power Door Lock Switch: Testing and Inspection Left Front
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Left Front > Page 10589
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Left Front > Page 10590
Power Door Lock Switch: Testing and Inspection Right Front
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection > Left Front > Page 10591
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 10595
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 10596
Power Mirror Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Locations > Page 10597
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Left
Power Seat Switch: Diagrams Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Diagrams > Left > Page 10602
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service Precautions > Technician Safety Information
Power Seat Switch: Technician Safety Information
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service Precautions > Technician Safety Information > Page 10605
Power Seat Switch: Vehicle Damage Warnings
CAUTION:
- To prevent damage to the side shield, the clips must be depressed in order to release the side
shield from the cushion pan.
- Use care when disconnecting the seat cushion side shield from the seat cushion frame so the
tabs on the seat cushion side shield are not damaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Seat Memory Set Switch
Power Seat Switch: Testing and Inspection Seat Memory Set Switch
Remove the memory set switch. Measure the resistance between the indicated terminals while
pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the
calling Pinpoint Test.
To check the memory set switch LED, connect the positive meter lead to terminal 8 and the
negative lead to terminal 9. The meter should indicate greater than 0.3 volts. Reversing the leads,
the meter should read OL.
If the meter readings are not as indicated above, replace the switch; otherwise, return to the calling
Pinpoint Test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Testing and Inspection > Seat Memory Set Switch > Page 10608
Power Seat Switch: Testing and Inspection Seat Regulator Control Switch
Remove the seat regulator control switch. Measure the resistance between the indicated terminals
while pressing the requested switches.
The resistance should be less than 5 ohms for each switch position.
If the resistance is not less than 5 ohms for each switch, replace the switch; otherwise, return to the
calling Pinpoint Test.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Sport Bucket
Power Seat Switch: Service and Repair Sport Bucket
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket,
3. Remove the lumbar support knob.
4. Remove the rear side shield screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Sport Bucket > Page 10611
5. Release the side shield clips.
CAUTION: To prevent damage to the side shield, the clips must be depressed in order to release
the side shield from the cushion pan.
6. Unhook the side shield from the seat latch.
7. If equipped, disconnect the heated seat switch electrical connector.
8. Remove the side shield.
1 Disconnect the electrical connector.
2 Remove the side shield.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Sport Bucket > Page 10612
9. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
1. To install, reverse the removal procedure. 2. Reactivate the supplemental restraint system. For
additional information, refer to Air Bag Systems. 3. Prove out the air bag system. For additional
information, refer to Air Bag Systems. 4. Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Sport Bucket > Page 10613
Power Seat Switch: Service and Repair Limited
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Sport Bucket > Page 10614
5. Remove the front seat cushion side shield screws.
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Disconnect the lumbar support control switch electrical connector.
8. Disconnect the lumbar support adjusting hoses from the adjusting switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component
Information > Service and Repair > Sport Bucket > Page 10615
9. If equipped, disconnect the heated seat switch electrical connector.
10. Remove the front seat cushion side shield.
11. Remove the 6-way power seat switch.
1 Remove the screws.
2 Remove the 6-way power seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Diagrams > Left
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Diagrams > Left > Page 10620
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Sport Bucket
Seat Heater Switch: Service and Repair Sport Bucket
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Remove the lumbar support knob.
4. Remove the rear side shield screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Sport Bucket > Page 10623
5. Release the side shield clips.
6. Disconnect the heated seat switch electrical connector.
7. Remove the heated seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Sport Bucket > Page 10624
Seat Heater Switch: Service and Repair Limited
REMOVAL
WARNING:
- ALWAYS WEAR SAFETY GLASSES WHEN REPAIRING AN AIR BAG SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) VEHICLE AND WHEN HANDLING AN AIR BAG MODULE. THIS
WILL REDUCE THE RISK OF INJURY IN THE EVENT OF AN ACCIDENTAL DEPLOYMENT.
- AFTER DEPLOYMENT, THE AIR BAG SURFACE CAN CONTAIN DEPOSITS OF SODIUM
HYDROXIDE, A PRODUCT OF THE GAS GENERANT COMBUSTION THAT IS IRRITATING TO
THE SKIN. WASH YOUR HANDS WITH SOAP AND WATER AFTERWARD.
- THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM SERVICE
ONLY. REMOVE FROM VEHICLE PRIOR TO ROAD USE. FAILURE TO REMOVE COULD
RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY STANDARDS.
NOTE:
- If a seat equipped with a seat mounted side airbag system is being serviced the airbag system
must be deactivated per the deactivation procedure contained in Air Bag Systems.
- Airbag simulators (restraint system diagnostic tools) MUST be installed under the seats in the
side airbag to floor connector.
- Diagnostics or repairs are not to be performed on a side airbag system with the seat in the
vehicle. Prior to attempting to diagnose/repair the side airbag system the seat must be removed
from the vehicle and the restraint system diagnostic tool must be installed in side airbag connector
at the floor connector. The restraint system diagnostic tool must be removed prior to operating the
vehicle.
- Diagnostics may be performed on seat Systems other than the side airbag system (lumbar,
climate controlled, heated, power seat track) with the seat installed in the vehicle as long as the
restraint system diagnostic tool is installed under the seat in the side airbag to floor connector.
- After diagnosing/repairing a seat system the restraint system diagnostic tool must be removed
before operating the vehicle.
1. Deactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems.
2. Remove the front seat. For additional information, refer to Seat-Front Bucket.
NOTE: Be sure to read and follow all air bag warnings contained in Seat-Front Bucket, Removal
and Installation.
3. Disconnect the power seat switch electrical connector.
4. Remove the front seat cushion side shield rear screw.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Sport Bucket > Page 10625
5. Remove the front seat cushion side shield screws.
6. Disconnect the front seat cushion side shield.
CAUTION: Use care when disconnecting the seat cushion side shield from the seat cushion frame
so the tabs on the seat cushion side shield are not damaged.
7. Disconnect the lumbar support control switch electrical connector.
8. Disconnect the lumbar support adjusting hoses from the adjusting switch.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component
Information > Service and Repair > Sport Bucket > Page 10626
9. Disconnect the heated seat switch electrical connector.
10. Remove the front seat cushion side shield.
11. Remove the heated seat switch.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE RESTRAINT SYSTEM DIAGNOSTIC TOOL IS FOR RESTRAINT SYSTEM
SERVICE ONLY. REMOVE FROM THE VEHICLE PRIOR TO ROAD USE. FAILURE TO
REMOVE COULD RESULT IN INJURY AND POSSIBLE VIOLATION OF VEHICLE SAFETY
STANDARDS.
2. Reactivate the supplemental restraint system. For additional information, refer to Air Bag
Systems. 3. Prove out the air bag system. For additional information, refer to Air Bag Systems. 4.
Check the restraint system for proper operation.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 10636
Trunk / Liftgate Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch >
Component Information > Diagrams > Page 10637
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Description and
Operation
Sound Proofing / Insulation: Description and Operation
INSULATION
Insulation is installed:
- under the hood.
- above and below the instrument panel.
- at the A-pillar lower trim panel.
- over the front and rear tunnel.
- over the front and rear floor pans.
- inside the B-pillar.
- inside the C-pillar.
- inside the D-pillar (Explorer Sport).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and
Repair
Cowl Moulding / Trim: Service and Repair
COWL PANEL GRILLE
Removal and Installation
1. Disconnect the driver side windshield washer hose from inside the engine compartment.
2. Remove the windshield wiper pivot arms.
1. Slide the clip so the windshield wiper pivot arm will clear the windshield wiper pivot shaft. 2. Pull
the windshield wiper pivot arm from the windshield wiper pivot shaft.
3. Remove the cowl grille screw.
4. Remove the driver side cowl grille.
- Pull up on the cowl grille to disengage the clips.
5. Remove the passenger side cowl grille.
- Pull up on the cowl grille to disengage the clips and disconnect the washer hose.
6. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control
Deactivation Switch
Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10659
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10660
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10661
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10662
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10663
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10664
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10665
Attachment III - Technical Information
Table of Contents
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10666
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10667
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10668
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10669
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10670
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10671
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10672
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10673
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10674
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10675
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10676
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10677
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10678
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10679
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10680
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10681
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10682
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10683
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch
Inspection > Page 10684
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control
Fire Hazard
Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control
Fire Hazard > Page 10689
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA09V399000 > Oct > 09 > Recall
09V399000: Cruise Control Deactivation Switch
Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control
Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10699
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10700
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10701
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10702
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10703
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10704
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10705
Attachment III - Technical Information
Table of Contents
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10706
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10707
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10708
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10709
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10710
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10711
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10712
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10713
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10714
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10715
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10716
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10717
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10718
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10719
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10720
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10721
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10722
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10723
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 > Recall - Cruise
Control Deactivation Switch Inspection > Page 10724
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall
07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control
Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): > NHTSA07V336000 > Aug > 07 > Recall
07V336000: Cruise Control Fire Hazard > Page 10729
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Technical Service
Bulletins > Page 10730
Brake Switch (Cruise Control): Specifications
Deactivator Switch 15-20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Technician Safety Information
Brake Switch (Cruise Control): Technician Safety Information
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Technician Safety Information > Page 10733
Brake Switch (Cruise Control): Vehicle Damage Warnings
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Service Precautions
> Page 10734
Brake Switch (Cruise Control): Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the deactivator switch electrical connector.
3. Remove the deactivator switch.
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE
^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles)
or more to relearn the strategy.
^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating
Technical Service Bulletin # 09S09 Date: 091013
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
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Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on October 13, 2009.
NOTE:
This recall pertains to certain vehicles that have a factory installed speed control deactivation
switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering
wheel identical to the factory-installed system. The Ford accessory kit does not use a master
cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this
recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in
OASIS under 09509, the vehicle is not involved in the program.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and
addresses will be available by December 18, 2009.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10744
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the
vehicle.
^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair
was performed prior to the date indicated in the reimbursement plan, which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or, at their option,
directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan.
Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control
deactivation switch.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 09S09 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS
adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on
same repair line as repair.)
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $6.30
^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness
connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair
line as repair.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10745
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $0.50
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10746
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this safety recall is 50409.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Affected speed control deactivation switches and related damage parts are subject to random
selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS
(Parts Entry and Return System) register for part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10747
TABLE OF CONTENTS
OVERVIEW
This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS)
harness connector for the presence of brake fluid contamination. If no brake fluid is present, install
the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the
speed control servo harness connector for heat damage. See Flow Chart # 2.
In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the
Anti-lock Brake System (ABS) connectors. See Flow Chart # 2.
If a related damage condition is found that you believe to be caused by a leaking SCDS, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
REPAIR FLOW CHARTS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10748
Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003
Windstar vehicles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10749
Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles.
SCDS Identification
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10750
The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised
SCDS are illustrated (See Figure 1).
Note that the revised SCDS has a different electrical connector An adapter jumper harness (which
is included in the parts kit) is required when replacing the old SCDS with the revised SCDS
SCDS Location
In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993
E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve
on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located
on the junction block or brake proportioning valve on the left frame rail below the master cylinder
To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53
Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
SCDS INSPECTION PROCEDURE
NOTE:
For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If
unable to locate a SCDS after checking on all the brake lines, no further action is required, release
the vehicle
NOTE:
On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain
access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle
to gain access to the SCDS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
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1. Disconnect the harness connector from the SCDS (See Figure 2)
2. Inspect the harness connector for the presence of brake fluid.
^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness
(UFJH).
^ If there is evidence of brake fluid on the connector, replace SCDS.
UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION
1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness.
2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are
positioned vertically with the fuse holder cap facing upward
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10752
Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse
holder orientation (See Figure 3).
3. No further action is required release the vehicle.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US),
CPM-1-C (Canada), to the fluid port at the
threaded end of the new SCDS (See Figure 4).
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed
3. Remove the old SCDS.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed
from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft).
5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake
fluid reservoir cap.
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6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II
(XG-15-A) (See Figure 5).
7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the adapter jumper
harness to a nearby component such as the speed control cable or another wire harness.
^ If the vehicle has a speed control servo, proceed with speed control servo inspection.
^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS
inspection.
^ If none of the above apply, no further action is required, release the vehicle.
SPEED CONTROL SERVO INSPECTION
1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage
(See Figure 6)
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector) proceed to step 2 for further instructions.
^ If heat damage is found proceed as follows:
- 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center
for further instructions.
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Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
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- All other vehicles call the Special Service Support Center for further instructions.
2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from
the speed control servo harness electrical
connector and the servo module. Do not use any type of solvent to clean the connectors.
3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire
width and length of the servo vehicle harness
connector (See Figure 7).
NOTICE:
Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT
apply the grease directly to the connector of the servo module.
4. Reconnect the harness to the servo module.
5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is
required, release the vehicle.
ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION
NOTE:
This inspection applies to 1999 through 2003 Windstar vehicles only.
1. Lift vehicle and remove ABS cover.
2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of
brake fluid.
3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness
connector and module.
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Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10755
4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure
8).
5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module
connector call the Special Service Support Center for
further instructions.
6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS
module.
7. Is the speed control servo heat damaged?
^ If the speed control servo is heat damaged call the Special Service Support Center for further
instructions.
^ If the speed control servo is not heat damaged no further action is required release the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10756
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation Switch Overheating > Page
10757
Owner Letter
Owner Letter not available at this time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating
Technical Service Bulletin # 09S09 Date: 091013
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10763
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on October 13, 2009.
NOTE:
This recall pertains to certain vehicles that have a factory installed speed control deactivation
switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering
wheel identical to the factory-installed system. The Ford accessory kit does not use a master
cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this
recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in
OASIS under 09509, the vehicle is not involved in the program.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and
addresses will be available by December 18, 2009.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10764
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the
vehicle.
^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair
was performed prior to the date indicated in the reimbursement plan, which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or, at their option,
directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan.
Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control
deactivation switch.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 09S09 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS
adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on
same repair line as repair.)
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $6.30
^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness
connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair
line as repair.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10765
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $0.50
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10766
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this safety recall is 50409.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Affected speed control deactivation switches and related damage parts are subject to random
selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS
(Parts Entry and Return System) register for part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10767
TABLE OF CONTENTS
OVERVIEW
This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS)
harness connector for the presence of brake fluid contamination. If no brake fluid is present, install
the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the
speed control servo harness connector for heat damage. See Flow Chart # 2.
In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the
Anti-lock Brake System (ABS) connectors. See Flow Chart # 2.
If a related damage condition is found that you believe to be caused by a leaking SCDS, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
REPAIR FLOW CHARTS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10768
Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003
Windstar vehicles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10769
Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles.
SCDS Identification
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10770
The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised
SCDS are illustrated (See Figure 1).
Note that the revised SCDS has a different electrical connector An adapter jumper harness (which
is included in the parts kit) is required when replacing the old SCDS with the revised SCDS
SCDS Location
In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993
E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve
on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located
on the junction block or brake proportioning valve on the left frame rail below the master cylinder
To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53
Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
SCDS INSPECTION PROCEDURE
NOTE:
For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If
unable to locate a SCDS after checking on all the brake lines, no further action is required, release
the vehicle
NOTE:
On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain
access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle
to gain access to the SCDS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10771
1. Disconnect the harness connector from the SCDS (See Figure 2)
2. Inspect the harness connector for the presence of brake fluid.
^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness
(UFJH).
^ If there is evidence of brake fluid on the connector, replace SCDS.
UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION
1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness.
2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are
positioned vertically with the fuse holder cap facing upward
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10772
Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse
holder orientation (See Figure 3).
3. No further action is required release the vehicle.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US),
CPM-1-C (Canada), to the fluid port at the
threaded end of the new SCDS (See Figure 4).
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed
3. Remove the old SCDS.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed
from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft).
5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake
fluid reservoir cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10773
6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II
(XG-15-A) (See Figure 5).
7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the adapter jumper
harness to a nearby component such as the speed control cable or another wire harness.
^ If the vehicle has a speed control servo, proceed with speed control servo inspection.
^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS
inspection.
^ If none of the above apply, no further action is required, release the vehicle.
SPEED CONTROL SERVO INSPECTION
1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage
(See Figure 6)
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector) proceed to step 2 for further instructions.
^ If heat damage is found proceed as follows:
- 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center
for further instructions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10774
- All other vehicles call the Special Service Support Center for further instructions.
2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from
the speed control servo harness electrical
connector and the servo module. Do not use any type of solvent to clean the connectors.
3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire
width and length of the servo vehicle harness
connector (See Figure 7).
NOTICE:
Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT
apply the grease directly to the connector of the servo module.
4. Reconnect the harness to the servo module.
5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is
required, release the vehicle.
ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION
NOTE:
This inspection applies to 1999 through 2003 Windstar vehicles only.
1. Lift vehicle and remove ABS cover.
2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of
brake fluid.
3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness
connector and module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10775
4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure
8).
5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module
connector call the Special Service Support Center for
further instructions.
6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS
module.
7. Is the speed control servo heat damaged?
^ If the speed control servo is heat damaged call the Special Service Support Center for further
instructions.
^ If the speed control servo is not heat damaged no further action is required release the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10776
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise Control Deactivation
Switch Overheating > Page 10777
Owner Letter
Owner Letter not available at this time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications
Cruise Control Servo: Specifications
Speed Control Servo Bracket Bolt 9-12 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 10781
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 10782
Cruise Control Servo: Service Precautions
WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND
THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 10783
Cruise Control Servo: Service and Repair
REMOVAL
1. Disconnect the speed control servo electrical connector.
2. Remove the speed control actuator cable cap from the speed control servo.
^ Push the locking arm on the speed control actuator cable cap then rotate the cap
counterclockwise.
3. Disconnect the speed control core wire end from the speed control servo pulley.
1 Depress the spring retainer.
2 Slide the core wire end out of the speed control servo pulley.
4. Remove the speed control servo bracket bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 10784
5. Remove the speed control servo.
INSTALLATION
1. Install the speed control servo bracket bolt.
2. Insert the speed control cable slug into the speed control servo pulley slot.
1 Gently compress the speed control servo spring.
2 Insert the speed control cable slug into the speed control servo pulley slot.
3. Release the compressed spring while aligning the speed control actuator cable cap tabs with the
slots in the speed control servo housing.
WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND
THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION.
NOTE: Make sure the rubber seal is fully seated onto the speed control actuator cable cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Specifications > Page 10785
4. Rotate the speed control actuator cable cap until the locking arm engages.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement
Technical Service Bulletin # 03S03 Date: 030801
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10794
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10795
Attachment I - Administrative Information
OASIS
Use OASIS to determine if a vehicle is eligible for this recall.
Note:
Some of the vehicles affected by this program are also affected by program 03S04. Affected
customers will receive one letter describing both programs. For customer convenience please
perform both programs during one customer visit.
PROMPTLY CORRECT
Promptly correct all affected in-stock and sold vehicles on your FSA VIN Lists. Also correct other
affected vehicles identified in OASIS which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any of your affected owners whose names are not on your VIN lists but
identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date.
Note:
Your FSA VIN list may contain customer names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states provinces and countries.
Accordingly you must limit the use of this listing to the follow- up necessary to complete this action.
Advise regional office if an owner cannot be contacted or does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the
repair was performed prior to the date indicated in the reimbursement plan which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or at their option
directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121.
Dealers are also authorized to refund owner-paid emergency repairs that were performed away
from an authorized servicing dealer after the end date
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10796
specified in the reimbursement plan.
Refund Claiming Information
Program Code: 03S03
Misc. Expense: REFUND
Misc. Expense: ADMIN
Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below. For the first 30 days after program launch emergency status
orders can be placed by calling the Special Service Support Center at 1-800-325-5621.
^ For Stock Orders effective immediately follow normal order process.
^ For Interim Orders effective immediately follow normal order process.
^ For Emergency Orders within the first 30 days after launch call 1-800-325-5621. For Emergency
Orders 31 days after launch follow normal order process.
The DOR/COR for this program is 50308. This number identifies parts ordered for this recall
through the Special Service Support Center (1-800-325-5621).
USE OF "CHECKING GAUGE"
A "Checking Gauge" is utilized in this recall during Step 6 of the Technical Instructions.
Gauges will be shipped to the dealership (quantity of 4 gauges per dealer). It is expected that tools
will arrive at the dealership the week of September 2, 2003. A limited number of additional gauges
may be ordered at no-charge by calling the Special Service Support Center at 1-800-325-5621.
Alternatively, dealers can use an accurate measuring device such as digital calipers.
PARTS RETENTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10797
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
DEALER PRICE
For latest prices, refer to DOES II or updated price book.
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
INSPECTION
1. Locate the speed control cable identification number. Read the second to last letter. See Figure
1.
^ If the letter is a "T", no service is required. Release the vehicle. If the letter is a "D", continue with
this inspection.
2. Remove the snow/ice shield. See Figure 2.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10798
3. Visually inspect the cable for any of the following unacceptable conditions (see Figure 3):
^ Cover flared or split.
^ Core wire exposed when no tension is applied to the cable.
^ Cable is kinked.
Replace the cable if any of the above conditions are found. For replacement and adjustment
procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual.
If none of these conditions are found, continue with the next step of this procedure.
4. WARNING: BE SURE TO MARK THE STRAND COVER AT THE VERY POINT WHERE IT
ENTERS THE NOTCHED CABLE HOUSING. FAILURE TO MARK THE COVER AND MEASURE
THE DISTANCE ACCURATELY (AS OUTLINED IN STEP 6) MAY RESULT IN FAILURE TO
REPLACE AN UNACCEPTABLE CABLE.
NOTE:
Use a suitable marker such as a fine point paint marker or a felt-tipped marking pen. Brush-on
touchup paint may also be used. DO NOT use a blunt marker or one that has a worn-out tip. It
could cause your measurement to be incorrect. Whichever marking device you decide to use, it
must leave a clean, straight line at the very point where the strand cover enters the notched cable
housing. You will be measuring, in very small increments, the distance from the very edge of the
mark you make to a certain point on the cable assembly. THE MEASUREMENT MUST NOT
INCLUDE THE THICKNESS OF THE MARK.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10799
Clean the cable if necessary, then using a suitable marking device, mark the strand cover at the
point where the cover enters the notched cable housing. See Figure 4.
5. Disconnect the speed control cable connector from the throttle body cam by pulling the
connector upward. See Figure 4.
6. CAUTION: When performing the following check, you will be instructed to pull the connector taut.
Use only your hand to pull the connector. DO NOT use any type of tool to do this or damage to the
cable may occur.
CAUTION:
Do not grasp the cable so tightly that you will kink the cable.
NOTE:
When pulling the connector, the strand cover may or may not be pulled out of the notched cable
housing. For the purpose of this inspection, either is acceptable.
NOTE:
The following check can be made using either the 4 mm checking gauge supplied to each
dealership or a Vernier caliper (analog dial or electronic LCD display).
Pull the connector taut (toward the front of the vehicle). See Figure 5.
A) If the strand cover does not pull out of the notched cable housing, no further service is required.
Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10800
B) If the strand cover is pulled out of the notched cable housing, using either the supplied 4 mm
checking gauge or a Vernier caliper, measure the distance from the inside edge of the mark to the
end of the exposed strand cover. Do not include the thickness of the mark when taking the
measurement. See Figures 5 and 6.
^ If the measurement is 4 mm (5/32-inch or 0.157-inch) or greater, no further service is required.
Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle.
^ If the measurement is less than 4 mm (5/32-inch or 0.157-inch), the speed control cable must be
replaced. For replacement and adjustment
procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10801
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Recalls for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control Cable
Inspection/Replacement > Page 10802
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement
Technical Service Bulletin # 03S03 Date: 030801
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10808
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10809
Attachment I - Administrative Information
OASIS
Use OASIS to determine if a vehicle is eligible for this recall.
Note:
Some of the vehicles affected by this program are also affected by program 03S04. Affected
customers will receive one letter describing both programs. For customer convenience please
perform both programs during one customer visit.
PROMPTLY CORRECT
Promptly correct all affected in-stock and sold vehicles on your FSA VIN Lists. Also correct other
affected vehicles identified in OASIS which are brought to your dealership.
DEALER-OWNER CONTACT
Immediately contact any of your affected owners whose names are not on your VIN lists but
identified in OASIS. Give the owner a copy of the Owner Letter and schedule a service date.
Note:
Your FSA VIN list may contain customer names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states provinces and countries.
Accordingly you must limit the use of this listing to the follow- up necessary to complete this action.
Advise regional office if an owner cannot be contacted or does not make a service date.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
OWNER REFUNDS
Ford Motor Company is offering a refund for owner-paid repairs covered by this Safety Recall if the
repair was performed prior to the date indicated in the reimbursement plan which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or at their option
directly through Ford Motor Company at P.O. Box 1904, Dearborn, MI 48121.
Dealers are also authorized to refund owner-paid emergency repairs that were performed away
from an authorized servicing dealer after the end date
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10810
specified in the reimbursement plan.
Refund Claiming Information
Program Code: 03S03
Misc. Expense: REFUND
Misc. Expense: ADMIN
Misc. Expense: 0.2 Hrs.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
PARTS REQUIREMENTS / ORDERING INFORMATION
Parts will not be direct shipped for this recall. Order your parts requirements through normal order
processing channels as noted below. For the first 30 days after program launch emergency status
orders can be placed by calling the Special Service Support Center at 1-800-325-5621.
^ For Stock Orders effective immediately follow normal order process.
^ For Interim Orders effective immediately follow normal order process.
^ For Emergency Orders within the first 30 days after launch call 1-800-325-5621. For Emergency
Orders 31 days after launch follow normal order process.
The DOR/COR for this program is 50308. This number identifies parts ordered for this recall
through the Special Service Support Center (1-800-325-5621).
USE OF "CHECKING GAUGE"
A "Checking Gauge" is utilized in this recall during Step 6 of the Technical Instructions.
Gauges will be shipped to the dealership (quantity of 4 gauges per dealer). It is expected that tools
will arrive at the dealership the week of September 2, 2003. A limited number of additional gauges
may be ordered at no-charge by calling the Special Service Support Center at 1-800-325-5621.
Alternatively, dealers can use an accurate measuring device such as digital calipers.
PARTS RETENTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10811
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
DEALER PRICE
For latest prices, refer to DOES II or updated price book.
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
INSPECTION
1. Locate the speed control cable identification number. Read the second to last letter. See Figure
1.
^ If the letter is a "T", no service is required. Release the vehicle. If the letter is a "D", continue with
this inspection.
2. Remove the snow/ice shield. See Figure 2.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10812
3. Visually inspect the cable for any of the following unacceptable conditions (see Figure 3):
^ Cover flared or split.
^ Core wire exposed when no tension is applied to the cable.
^ Cable is kinked.
Replace the cable if any of the above conditions are found. For replacement and adjustment
procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual.
If none of these conditions are found, continue with the next step of this procedure.
4. WARNING: BE SURE TO MARK THE STRAND COVER AT THE VERY POINT WHERE IT
ENTERS THE NOTCHED CABLE HOUSING. FAILURE TO MARK THE COVER AND MEASURE
THE DISTANCE ACCURATELY (AS OUTLINED IN STEP 6) MAY RESULT IN FAILURE TO
REPLACE AN UNACCEPTABLE CABLE.
NOTE:
Use a suitable marker such as a fine point paint marker or a felt-tipped marking pen. Brush-on
touchup paint may also be used. DO NOT use a blunt marker or one that has a worn-out tip. It
could cause your measurement to be incorrect. Whichever marking device you decide to use, it
must leave a clean, straight line at the very point where the strand cover enters the notched cable
housing. You will be measuring, in very small increments, the distance from the very edge of the
mark you make to a certain point on the cable assembly. THE MEASUREMENT MUST NOT
INCLUDE THE THICKNESS OF THE MARK.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10813
Clean the cable if necessary, then using a suitable marking device, mark the strand cover at the
point where the cover enters the notched cable housing. See Figure 4.
5. Disconnect the speed control cable connector from the throttle body cam by pulling the
connector upward. See Figure 4.
6. CAUTION: When performing the following check, you will be instructed to pull the connector taut.
Use only your hand to pull the connector. DO NOT use any type of tool to do this or damage to the
cable may occur.
CAUTION:
Do not grasp the cable so tightly that you will kink the cable.
NOTE:
When pulling the connector, the strand cover may or may not be pulled out of the notched cable
housing. For the purpose of this inspection, either is acceptable.
NOTE:
The following check can be made using either the 4 mm checking gauge supplied to each
dealership or a Vernier caliper (analog dial or electronic LCD display).
Pull the connector taut (toward the front of the vehicle). See Figure 5.
A) If the strand cover does not pull out of the notched cable housing, no further service is required.
Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10814
B) If the strand cover is pulled out of the notched cable housing, using either the supplied 4 mm
checking gauge or a Vernier caliper, measure the distance from the inside edge of the mark to the
end of the exposed strand cover. Do not include the thickness of the mark when taking the
measurement. See Figures 5 and 6.
^ If the measurement is 4 mm (5/32-inch or 0.157-inch) or greater, no further service is required.
Reattach the connector to the throttle body cam, install the snow/ice shield and release the vehicle.
^ If the measurement is less than 4 mm (5/32-inch or 0.157-inch), the speed control cable must be
replaced. For replacement and adjustment
procedures, refer to Section 310-03, Vehicle Speed Control of the appropriate workshop manual.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10815
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Cruise Control Servo Cable: > 03S03 > Aug > 03 > Recall - Speed Control
Cable Inspection/Replacement > Page 10816
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Technical Service
Bulletins > Page 10817
Cruise Control Servo Cable: Specifications
Accelerator Control Splash Shield Bolt (4.0L [Push Rod], 5.0L) .......... 8-12 Nm ............
(71-106Lb-In) Accelerator Control Splash Shield Bolts (4.0L SOHC) ......................... 3.1-4.3 Nm
........ (2.5-3 Lb-Ft) Battery Ground Cable .......................................................................7-10 Nm
............ (62-89 Lb-In) Speed Control Actuator Cable Bolt .....................................................3.1-4.3
Nm ........ (27-38 Lb-In)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions >
Technician Safety Information
Cruise Control Servo Cable: Technician Safety Information
WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND
THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions >
Technician Safety Information > Page 10820
Cruise Control Servo Cable: Vehicle Damage Warnings
CAUTION: The guide pin must be fully seated before installing the speed control actuator cable
bolt.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions >
Page 10821
Cruise Control Servo Cable: Adjustments
REMOVAL
1. Remove the speed control actuator cable clip.
2. Adjust the speed control actuator cable.
1 Make sure the throttle body cam is in the closed position.
2 Pull on the speed control actuator cable to remove any slack.
3 Back off the speed control actuator cable one notch.
NOTE
^ The speed control actuator cable must not be pulled tight for proper operation.
^ The throttle body cam will automatically spring set to the closed position. The throttle body cam
must be in the closed position.
INSTALLATION
1. Install the speed control actuator cable clip.
1 Hold the speed control actuator cable.
2 Insert the speed control actuator clip securely.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions >
Page 10822
Cruise Control Servo Cable: Service and Repair
REMOVAL
1. Remove the accelerator control splash shield. Remove the bolts.
2. Remove the speed control actuator cable .
1 Remove the bolt.
2 Remove the speed control actuator cable from the throttle linkage.
3. Remove the speed control actuator cable cap from the speed control servo.
^ Push in the locking arm on the speed control actuator cable cap then rotate the cap
counterclockwise.
4. Disconnect the speed control core wire end from the speed control servo pulley.
1 Depress the spring retainer.
2 Slide the core wire end out of the speed control servo pulley.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions >
Page 10823
INSTALLATION
1. Insert the speed control cable slug into the speed control servo pulley slot.
1 Gently compress the speed control servo spring.
2 Insert the speed control cable slug into the speed control servo pulley slot.
2. Release the compressed spring while aligning the speed control actuator cable cap tabs with the
slots in the speed control servo housing.
WARNING: INCORRECT WRAPPING OF THE SPEED CONTROL ACTUATOR CABLE AROUND
THE SPEED CONTROL SERVO PULLEY MAY RESULT IN A HIGH IDLE CONDITION.
NOTE: Make sure the rubber seal is fully seated onto the speed control actuator cable cap.
3. Rotate the speed control actuator cable cap until the locking arm engages.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service Precautions >
Page 10824
4. Snap the speed control actuator cable and the accelerator cable together in the clip and install
the cables onto the accelerator cable bracket.
CAUTION: The guide pin must be fully seated before installing the speed control actuator cable
bolt.
5. Position the accelerator control splash shield and install the bolts.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins >
Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch
Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise
Control Deactivation Switch
Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control
Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins >
Page 10838
Cruise Control Switch: Specifications
Speed Control Actuator Switch Screws 6.5-7.5 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins >
Page 10839
Cruise Control Switch: Service Precautions
CAUTION: When separating the speed control actuator switch from the steering wheel, it is
necessary to take precautions not to damage the steering wheel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair >
Without Remote Audio
Cruise Control Switch: Service and Repair Without Remote Audio
REMOVAL
1. Remove the driver side air bag module. Refer to Air Bag Systems.
2. Remove the speed control actuator switches.
1 Remove the screws.
2 Disconnect the electrical connector then remove the speed control actuator switches.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10
miles) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Service and Repair >
Without Remote Audio > Page 10842
Cruise Control Switch: Service and Repair With Remote Audio
REMOVAL
1. Disconnect the battery ground cable.
2. Separate the speed control actuator switch out of the steering wheel.
CAUTION: When separating the speed control actuator switch from the steering wheel, it is
necessary to take precautions not to damage the steering wheel.
3. Remove the speed control actuator switch.
1 Disconnect the speed control actuator switch electrical connector.
2 Remove the speed control actuator switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn its strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA09V399000 >
Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch
Brake Switch (Cruise Control): Recalls Recall 09V399000: Cruise Control Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10856
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10857
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10858
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10859
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10860
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10861
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10862
Attachment III - Technical Information
Table of Contents
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10863
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10864
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10865
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10866
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10867
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10868
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10869
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10870
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10871
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10872
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10873
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10874
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10875
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10876
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10877
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10878
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10879
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10880
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > 05S28S15 > Apr > 08 >
Recall - Cruise Control Deactivation Switch Inspection > Page 10881
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 >
Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): Recalls Recall 07V336000: Cruise Control Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Recalls for Brake Switch (Cruise Control): > NHTSA07V336000 >
Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10886
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA09V399000 > Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch
Brake Switch (Cruise Control): All Technical Service Bulletins Recall 09V399000: Cruise Control
Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection
Technical Service Bulletin # 05S28S15 Date: 080410
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10896
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10897
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10898
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10899
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10900
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10901
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10902
Attachment III - Technical Information
Table of Contents
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10903
SCDS Identification
The Speed Control Deactivation Switch (SCDS) involved in Recall 05S28 and the revised SCDS is
illustrated below. See Figure 1.
Note that the revised SCDS has a different electrical connector. A jumper adapter (which is
included in the parts kit) is required when replacing the old SCDS with the revised SCDS.
SCDS Location
In most late model year vehicles involved in this recall, the SCDS is located on the master cylinder.
In early model year vehicles (1992-1998), the SCDS may be located on the master cylinder but is
often found on a brake line distribution block or on the brake proportioning valve. If in doubt, just
follow the metal brake lines from the master cylinder until the switch is found.
^ On early model year E-Series vehicles, the SCDS is located on the left frame rail.
^ On E-450 models only, remove the 3 screws and position the coolant degas bottle forward to
allow access to the SCDS and servo.
^ On F-53 vehicles, if the SCDS is not located on the master cylinder, it may be located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder. It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
^ On 1993 MARK VIII vehicles, the steering wheel intermediate shaft needs to be disconnected
from the inside of the vehicle and the outside of the vehicle, and then positioned upwards to gain
access to the SCDS.
- When the intermediate steering shaft is disconnected, the steering wheel must be in the LOCK
position to prevent damage to the clockspring.
- During installation of the intermediate steering shaft, new bolts must be installed. Tighten the bolts
to 49 Nm (36 lb-ft).
^ On 1994-1998 MARK VIII vehicles, the SCDS is located underneath the right front fender splash
shield in front of the right front wheel. It is not necessary to remove the right front wheel to access
the SCDS. Turn the wheel all the way right and position the front of the fender splash shield aside.
^ On all Mark VIII vehicles (except 1993), the speed control servo is located underneath the left
front fender splash shield in front of the left front wheel.
FUSED JUMPER HARNESS (FJH) IDENTIFICATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10904
The new universal fused jumper harness has a double fuse instead of a single fuse. See Figure 2.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10905
PARTS APPLICATION CHART
SPEED CONTROL DEACTIVATION SWITCH (SCDS) INSPECTION
NOTE:
On E-15012501350 and MARK VIII, it may be necessary to lift the vehicle to disconnect the SCDS.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10906
Disconnect the SCDS and inspect the harness connector (See Figure 3) for the presence of brake
fluid.
^ All vehicles except 1993 Mark VIII: If there is no evidence of brake fluid on the connector, install a
Fused Jumper Harness.
- On 1993 Mark VIII vehicles with no evidence of brake fluid on the SCDS harness connector,
replace the Speed Control Deactivation Switch but do not inspect or apply electrical grease to the
speed control servo connector.
^ If there is evidence of brake fluid on the connector, replace the Speed Control Deactivation
Switch, inspect and apply electrical grease to the appropriate connectors.
FUSED JUMPER HARNESS (FJH) INSTALLATION
1. Connect the fused jumper harness to the SCDS and the vehicle harness.
2. Secure the jumper harness to the existing harness with tie straps, making sure the fuse holders
are positioned vertically with the cap facing upward. Wrap the tie straps underneath, then over the
top of the existing harness and verify proper fuse holder orientation. See Figure 4.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and, if necessary, fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur.
NOTICE:
The 1994 Capri Brake Repair Kit contains a brass sealing washer. Install the brass washer onto the
SCDS before installing it on the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10907
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid, PM1-1 or
PM-1-C (US), CPM-1-C (Canada), to the fluid port at the threaded end of the new SCDS. See
Figure 5.
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program.
3. Remove the SCDS.
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed from the fitting, install the new SCDS.
5. Tighten the new SCDS as follows:
^ 18 Nm (159 lb-in) - all vehicles except 1994 Capri.
^ 13 Nm (115 lb-in) - 1994 Capri.
6. Check the brake fluid level at the master cylinder, fill to maximum fluid level and install the brake
fluid reservoir cap.
7. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage.
See Figure 6.
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector), proceed to the next step.
^ If the speed control servo connector is heat damaged, call the Special Service Support Center for
further instructions.
8. With the speed control servo disconnected, use shop air only to blow the SCDS harness
electrical connector and the servo connector dry of any trace of brake fluid. Do not use any type of
solvent to clean the connectors.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10908
9. Cut approximately 3 mm (1/8 in) off the grease tube applicator tip.
10. Before installing the jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II XG-15-A. See Figure 7.
11. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the jumper harness to a nearby component such as the speed
control cable or another wire harness.
NOTICE:
Be sure to apply and adequate amount of grease to the vehicle harness connector only. DO NOT
apply the grease directly to the connector of the servo module.
12. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II XG-15-A across the entire
width and length of the servo vehicle harness connector. See Figure 8.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10909
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10910
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10911
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10912
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10913
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10914
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10915
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10916
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10917
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10918
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10919
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10920
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
05S28S15 > Apr > 08 > Recall - Cruise Control Deactivation Switch Inspection > Page 10921
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard
Brake Switch (Cruise Control): All Technical Service Bulletins Recall 07V336000: Cruise Control
Fire Hazard
MAKE/MODELS: MODEL/BUILD YEARS: Ford/Bronco 1993 Ford/Crown Victoria 1992-1998
Ford/E-150 1997-2002 Ford/E-250 1997-2002 Ford/E-350 1997-2002 Ford/E150 1992-1993 2003
Ford/E250 1992-1993 2003 Ford/E350 1992-1993 2003 Ford/E450 2003 Ford/Explorer 1999-2001
Ford/Explorer Sport 2001-2002 Ford/Explorer Sport Trac 2001-2002 Ford/F-150 Lightning
2003-2004 Ford/F150 1993 Ford/F250 1993 Ford/F350 1993 Ford/F450 1993 Ford/F53 1995-2002
Ford/Ranger 1998-2002 Ford/Taurus SHO 1993-1995 Lincoln/Mark VIII 1993-1998 Lincoln/Town
Car 1992-1998 Mercury/Capri 1994 Mercury/Grand Marquis 1992-1998 Mercury/Mountaineer
1999-2001 MANUFACTURER: Ford Motor Company NHTSA CAMPAIGN ID NUMBER:
07V336000 MFR'S REPORT DATE: August 02, 2007
COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 3600000
SUMMARY: On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes
chassis, the speed control deactivation switch may, under certain conditions, leak internally and
then overheat, smoke, or burn.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Switch (Cruise Control): >
NHTSA07V336000 > Aug > 07 > Recall 07V336000: Cruise Control Fire Hazard > Page 10926
CONSEQUENCE: This could result in an underhood fire.
REMEDY: Dealers will install a fused wiring harness. Owners of the passenger cars included in this
campaign will be instructed to return their vehicles to their dealers to have the speed control
deactivation switch disconnected as an interim repair. As soon as repair parts are available
(expected October 2007), owners will be instructed to return to the dealers for installation of a
fused wiring harness. The recall is expected to begin on August 13, 2007, and mailing completed
by September 19, 2007. Owners may contact Ford at 1-800-392-3673.
NOTES: Ford recall No. 05S28S11. Customers may also contact The National Highway Traffic
Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to
http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Technical Service Bulletins > Page 10927
Brake Switch (Cruise Control): Specifications
Deactivator Switch 15-20 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service Precautions > Technician Safety Information
Brake Switch (Cruise Control): Technician Safety Information
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service Precautions > Technician Safety Information > Page 10930
Brake Switch (Cruise Control): Vehicle Damage Warnings
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Service Precautions > Page 10931
Brake Switch (Cruise Control): Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Disconnect the deactivator switch electrical connector.
3. Remove the deactivator switch.
WARNING: BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLYGLYCOLS. AVOID
CONTACT WITH EYES. WASH HANDS THOROUGHLY AFTER HANDLING. IF BRAKE FLUID
CONTACTS EYES, FLUSH EYES WITH RUNNING WATER FOR 15 MINUTES. GET MEDICAL
ATTENTION IF IRRITATION PERSISTS. IF TAKEN INTERNALLY, DRINK WATER AND INDUCE
VOMITING. GET MEDICAL ATTENTION IMMEDIATELY.
CAUTION: Brake fluid is harmful to painted and plastic surfaces. If brake fluid is spilled onto a
painted or plastic surface, immediately wash it with water.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE
^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles)
or more to relearn the strategy.
^ After the deactivator switch is installed, it is necessary to bleed the brake system; refer to Brakes.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating
Technical Service Bulletin # 09S09 Date: 091013
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10940
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on October 13, 2009.
NOTE:
This recall pertains to certain vehicles that have a factory installed speed control deactivation
switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering
wheel identical to the factory-installed system. The Ford accessory kit does not use a master
cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this
recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in
OASIS under 09509, the vehicle is not involved in the program.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and
addresses will be available by December 18, 2009.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10941
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the
vehicle.
^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair
was performed prior to the date indicated in the reimbursement plan, which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or, at their option,
directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan.
Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control
deactivation switch.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 09S09 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS
adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on
same repair line as repair.)
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $6.30
^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness
connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair
line as repair.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10942
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $0.50
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10943
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this safety recall is 50409.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Affected speed control deactivation switches and related damage parts are subject to random
selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS
(Parts Entry and Return System) register for part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10944
TABLE OF CONTENTS
OVERVIEW
This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS)
harness connector for the presence of brake fluid contamination. If no brake fluid is present, install
the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the
speed control servo harness connector for heat damage. See Flow Chart # 2.
In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the
Anti-lock Brake System (ABS) connectors. See Flow Chart # 2.
If a related damage condition is found that you believe to be caused by a leaking SCDS, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
REPAIR FLOW CHARTS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10945
Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003
Windstar vehicles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10946
Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles.
SCDS Identification
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10947
The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised
SCDS are illustrated (See Figure 1).
Note that the revised SCDS has a different electrical connector An adapter jumper harness (which
is included in the parts kit) is required when replacing the old SCDS with the revised SCDS
SCDS Location
In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993
E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve
on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located
on the junction block or brake proportioning valve on the left frame rail below the master cylinder
To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53
Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
SCDS INSPECTION PROCEDURE
NOTE:
For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If
unable to locate a SCDS after checking on all the brake lines, no further action is required, release
the vehicle
NOTE:
On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain
access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle
to gain access to the SCDS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10948
1. Disconnect the harness connector from the SCDS (See Figure 2)
2. Inspect the harness connector for the presence of brake fluid.
^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness
(UFJH).
^ If there is evidence of brake fluid on the connector, replace SCDS.
UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION
1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness.
2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are
positioned vertically with the fuse holder cap facing upward
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10949
Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse
holder orientation (See Figure 3).
3. No further action is required release the vehicle.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US),
CPM-1-C (Canada), to the fluid port at the
threaded end of the new SCDS (See Figure 4).
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed
3. Remove the old SCDS.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed
from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft).
5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake
fluid reservoir cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10950
6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II
(XG-15-A) (See Figure 5).
7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the adapter jumper
harness to a nearby component such as the speed control cable or another wire harness.
^ If the vehicle has a speed control servo, proceed with speed control servo inspection.
^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS
inspection.
^ If none of the above apply, no further action is required, release the vehicle.
SPEED CONTROL SERVO INSPECTION
1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage
(See Figure 6)
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector) proceed to step 2 for further instructions.
^ If heat damage is found proceed as follows:
- 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center
for further instructions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10951
- All other vehicles call the Special Service Support Center for further instructions.
2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from
the speed control servo harness electrical
connector and the servo module. Do not use any type of solvent to clean the connectors.
3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire
width and length of the servo vehicle harness
connector (See Figure 7).
NOTICE:
Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT
apply the grease directly to the connector of the servo module.
4. Reconnect the harness to the servo module.
5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is
required, release the vehicle.
ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION
NOTE:
This inspection applies to 1999 through 2003 Windstar vehicles only.
1. Lift vehicle and remove ABS cover.
2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of
brake fluid.
3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness
connector and module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10952
4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure
8).
5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module
connector call the Special Service Support Center for
further instructions.
6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS
module.
7. Is the speed control servo heat damaged?
^ If the speed control servo is heat damaged call the Special Service Support Center for further
instructions.
^ If the speed control servo is not heat damaged no further action is required release the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10953
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > Recalls for Clutch Switch: > 09S09 > Oct > 09 > Recall - Cruise
Control Deactivation Switch Overheating > Page 10954
Owner Letter
Owner Letter not available at this time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating
Technical Service Bulletin # 09S09 Date: 091013
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10960
Attachment I - Administrative Information
OASIS ACTIVATED?
Yes, OASIS will be activated on October 13, 2009.
NOTE:
This recall pertains to certain vehicles that have a factory installed speed control deactivation
switch only. Ford offered a Genuine Accessory Speed Control kit that utilized a production steering
wheel identical to the factory-installed system. The Ford accessory kit does not use a master
cylinder mounted deactivation switch and, as a result, vehicles with this kit are not included in this
recall. If a customer inquires about Safety Recall 09509, and the VIN of their vehicle is not listed in
OASIS under 09509, the vehicle is not involved in the program.
FSA VIN LIST ACTIVATED?
Yes, FSA VIN list will be available through the website by October 15, 2009. Owner names and
addresses will be available by December 18, 2009.
NOTE:
Your FSA VIN list may contain owner names and addresses obtained from motor vehicle
registration records. The use of such motor vehicle registration data for any purpose other than in
connection with this recall is a violation of law in several states, provinces, and countries.
Accordingly, you must limit the use of this listing to the follow-up necessary to complete this recall
action.
STOCK VEHICLES
Correct all affected units in your vehicle inventory before delivery.
SOLD VEHICLES
^ Owners of affected vehicles will be directed to dealers for repairs.
^ Immediately contact any of your affected owners whose vehicles are not on your VIN lists but are
identified in OASIS. Give the customer a copy of the Owner Notification Letter (when available) and
schedule a service date.
^ Correct other affected vehicles identified in OASIS which are brought to your dealership.
TITLE BRANDED / SALVAGED VEHICLES
Affected title branded and salvaged vehicles are eligible for this Field Service Action.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10961
RELATED DAMAGE
If a related damage condition exists that you believe to be caused by the covered condition, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted. Ford Motor Company
reserves the right to deny coverage for related damage in cases where the vehicle owner has not
had this recall performed on a timely basis.
ADDITIONAL LABOR TIME
^ If a condition exists that requires additional labor to complete the repair, call the Special Service
Support Center to request approval prior to performing any additional labor. Requests for approval
after completion of the repair will not be granted.
^ If you encounter aftermarket equipment or modifications to the vehicle which might prevent the
repair of the covered condition, call the Special Service Support Center.
OWNER REFUNDS
^ This safety recall must still be performed, even if the customer has paid for a previous repair.
Claiming a refund will not close the recall on the
vehicle.
^ Ford Motor Company is offering a refund for owner paid repairs covered by this recall if the repair
was performed prior to the date indicated in the reimbursement plan, which is posted with this
bulletin. This plan is also available to owners through the Customer Relationship Center (CRC).
The CRC will direct owners to seek reimbursement through authorized dealers or, at their option,
directly through Ford Motor Company at P.O. Box 6251 Dearborn, MI 48121-6251.
^ Dealers are also authorized to refund owner paid emergency repairs that were performed away
from an authorized servicing dealer after the end date specified in the reimbursement plan.
Non-covered repairs, or those judged by Ford to be excessive, will not be reimbursed.
^ Refunds will only be provided for the cost associated with repairs due to a leaking speed control
deactivation switch.
^ Refund Claiming Information (Submit on separate repair line.)
- Program Code: 09S09 - Misc. Expense: ADMIN
- Misc. Expense: REFUND - Misc. Expense: 0.2 Hrs.
^ Multiple refunds should be submitted on one repair line and the invoice details for each repair
should be detailed in the comments section of the claim. If a repair is performed on the same visit,
the repair and refunds should be submitted on separate repair lines.
RENTAL VEHICLES
The use of rental vehicles is not authorized for this program.
CLAIMS PREPARATION AND SUBMISSION
^ Enter claims using Direct Warranty Entry (DWE).
^ Refer to ACESII manual for claims preparation and submission information.
^ Refunds or related damage must be claimed on a repair line that is separate from the repair line
on which the FSA is claimed. Related damage requires prior approval from the Special Service
Support Center.
^ "MT" labor should be submitted on a separate repair line with the related damage flag checked.
"MT" labor requires prior approval from the Special Service Support Center.
^ Claiming information for Electrical Grease II for servicing both the speed control servo and SCDS
adapter jumper harness connector - applies to Labor Operation 09509G or 09S09H. (Submit on
same repair line as repair.)
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $6.30
^ Claiming information for Electrical Grease II for servicing SCDS adapter jumper harness
connector only - applies to Labor Operation 09509D, 09509F or 09509J (Submit on same repair
line as repair.)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10962
- Program Code: 09S09
- Misc. Expense: OTHER
- Misc. Expense: $0.50
Attachment II - Labor and Parts Information
LABOR ALLOWANCES
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10963
PARTS REQUIREMENTS / ORDERING INFORMATION
Order your parts requirements through normal order processing channels.
The DOR/COR number for this safety recall is 50409.
Questions regarding parts should be directed to the Special Service Support Center or E-mailed.
DEALER PRICE
For latest prices, refer to DOES II.
PARTS RETENTION AND RETURN
Affected speed control deactivation switches and related damage parts are subject to random
selection for return to the Ford Warranty Parts Analysis Center (WPAC). Refer to your daily PEARS
(Parts Entry and Return System) register for part disposition and return instructions.
Follow the provisions of the Warranty and Policy Manual for "Parts Retention and Return
Procedures."
EXCESS STOCK RETURN
Excess stock returned for credit must have been purchased from Ford Customer Service Division
in accordance with Policy Procedure Bulletin 4000.
Attachment III - Technical Information
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10964
TABLE OF CONTENTS
OVERVIEW
This Safety Recall involves an inspection of the Speed Control Deactivation Switch (SCDS)
harness connector for the presence of brake fluid contamination. If no brake fluid is present, install
the universal fused jumper harness. If brake fluid is present, replace the SCDS and inspect the
speed control servo harness connector for heat damage. See Flow Chart # 2.
In addition, for 1999 through 2003 Windstar vehicles, the repair includes an inspection of the
Anti-lock Brake System (ABS) connectors. See Flow Chart # 2.
If a related damage condition is found that you believe to be caused by a leaking SCDS, call the
Special Service Support Center to request approval prior to the repair of any related damage.
Requests for approval after completion of the repair will not be granted.
REPAIR FLOW CHARTS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10965
Flow Chart # 1 shows the repair procedure for all affected vehicles except 1999 through 2003
Windstar vehicles.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10966
Flow Chart # 2 shows the repair procedure for 1999 through 2003 Windstar vehicles.
SCDS Identification
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10967
The Speed Control Deactivation Switch (SCDS) involved in Safety Recall 09S09 and the revised
SCDS are illustrated (See Figure 1).
Note that the revised SCDS has a different electrical connector An adapter jumper harness (which
is included in the parts kit) is required when replacing the old SCDS with the revised SCDS
SCDS Location
In most vehicles involved in this recall, the SCDS is located on the master cylinder. In 1992-1993
E-Series vehicles, the SCDS is usually located on the junction block or brake proportioning valve
on the left frame rail under the driver's seat. In 1993 F-Series vehicles, the SCDS is usually located
on the junction block or brake proportioning valve on the left frame rail below the master cylinder
To verify, just follow the metal brake lines from the master cylinder until the switch is found On F-53
Motorhome vehicles, if the SCDS is not located on the master cylinder, it maybe located in a brake
line junction block approximately 457 mm (18 in) below the master cylinder It may be necessary to
reposition wiring harnesses and/or remove add-on equipment in order to locate the switch.
SCDS INSPECTION PROCEDURE
NOTE:
For E-Series vehicles, there is a possibility that the vehicle was manufactured without a SCDS If
unable to locate a SCDS after checking on all the brake lines, no further action is required, release
the vehicle
NOTE:
On 1992-1993 E-Series and 1993 F-Series vehicles, it may be necessary to lift the vehicle to gain
access to the SCDS On Windstar vehicles, the air cleaner housing must be separated in the middle
to gain access to the SCDS
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10968
1. Disconnect the harness connector from the SCDS (See Figure 2)
2. Inspect the harness connector for the presence of brake fluid.
^ If there is no evidence of brake fluid on the connector, install Universal Fused Jumper Harness
(UFJH).
^ If there is evidence of brake fluid on the connector, replace SCDS.
UNIVERSAL FUSED JUMPER HARNESS (UFJH) INSTALLATION
1. Connect the Universal Fused Jumper Harness (UFJH) to the SCDS and the vehicle harness.
2. Secure the UFJH to the existing harness with tie straps making sure the fuse holders are
positioned vertically with the fuse holder cap facing upward
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10969
Wrap the tie straps underneath then over the top of the existing harness and verify proper fuse
holder orientation (See Figure 3).
3. No further action is required release the vehicle.
SPEED CONTROL DEACTIVATION SWITCH (SCDS) REPLACEMENT
NOTE:
The brake pedal must not be depressed during the removal and replacement of the SCDS.
1. Check the brake fluid level at the master cylinder and if necessary fill to maximum fluid level.
NOTICE:
DO NOT apply fluid to the electrical connector or damage to the connector may occur
2. Add a few drops of Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid PM-1-C (US),
CPM-1-C (Canada), to the fluid port at the
threaded end of the new SCDS (See Figure 4).
NOTICE:
Do not allow any foreign material to enter the master cylinder port once the SCDS is removed
3. Remove the old SCDS.
NOTE:
Call the Special Service Support Center for assistance if brake fluid does not flow from the SCDS
fitting when the SCDS is removed.
NOTE:
If the new SCDS is not installed immediately after the original switch is removed, the master
cylinder brake fluid could drop below the minimum level and air could enter the brake system. If this
should occur, air must be bled from the brake system at all 4 wheels. In this situation, the labor to
bleed the brake system will not be covered under this program
4. With the brake fluid reservoir cap removed, observe for brake fluid dripping/draining from the
SCDS fitting. As soon as brake fluid begins to bleed
from the fitting, install the new SCDS and tighten to 18 Nm (13 lb-ft).
5. Check the brake fluid level at the master cylinder fill to maximum fluid level and install the brake
fluid reservoir cap.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10970
6. Before installing the adapter jumper harness, fill the vehicle harness end of the jumper (male pin
connector end) with Motorcraft Electrical Grease II
(XG-15-A) (See Figure 5).
7. Install the adapter jumper harness by connecting it to both the SCDS and the vehicle harness.
Using the provided tie strap, secure the adapter jumper
harness to a nearby component such as the speed control cable or another wire harness.
^ If the vehicle has a speed control servo, proceed with speed control servo inspection.
^ If the vehicle is a 1999-2003 Windstar that does not have speed control, proceed with ABS
inspection.
^ If none of the above apply, no further action is required, release the vehicle.
SPEED CONTROL SERVO INSPECTION
1. Disconnect the speed control servo and inspect the vehicle harness connector for heat damage
(See Figure 6)
^ If no heat damage is found at the speed control servo connector (even if there is presence of
brake fluid in the connector) proceed to step 2 for further instructions.
^ If heat damage is found proceed as follows:
- 1999-2003 Windstar complete ABS inspection before calling the Special Service Support Center
for further instructions.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10971
- All other vehicles call the Special Service Support Center for further instructions.
2. With the speed control servo disconnected use shop air to blow out any trace of brake fluid from
the speed control servo harness electrical
connector and the servo module. Do not use any type of solvent to clean the connectors.
3. Apply a 5 mm (3/16 in) high bead of Motorcraft Electrical Grease II (XG-15-A) across the entire
width and length of the servo vehicle harness
connector (See Figure 7).
NOTICE:
Be sure to apply an adequate amount of grease to the vehicle harness connector only DO NOT
apply the grease directly to the connector of the servo module.
4. Reconnect the harness to the servo module.
5. If the vehicle is a 1999-2OO3 Windstar proceed to ABS inspection. Otherwise no further action is
required, release the vehicle.
ANTI-LOCK BRAKE SYSTEM (ABS) INSPECTION
NOTE:
This inspection applies to 1999 through 2003 Windstar vehicles only.
1. Lift vehicle and remove ABS cover.
2. Disconnect ABS module. Inspect the ABS harness and module connectors for the presence of
brake fluid.
3. If brake fluid is present use shop air to blow out any trace of brake fluid from the harness
connector and module.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10972
4. Inspect the ABS harness and module connectors for corrosion and/or heat damage (See Figure
8).
5. If evidence of corrosion and/or heat damage is found in either the ABS harness or module
connector call the Special Service Support Center for
further instructions.
6. If there is no evidence of corrosion and/or heat damage reconnect the ABS harness to the ABS
module.
7. Is the speed control servo heat damaged?
^ If the speed control servo is heat damaged call the Special Service Support Center for further
instructions.
^ If the speed control servo is not heat damaged no further action is required release the vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10973
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch Switch: > 09S09 > Oct >
09 > Recall - Cruise Control Deactivation Switch Overheating > Page 10974
Owner Letter
Owner Letter not available at this time.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > Recalls for Cruise Control Switch: > NHTSA09V399000 > Oct > 09 > Recall
09V399000: Cruise Control Deactivation Switch
Cruise Control Switch: Recalls Recall 09V399000: Cruise Control Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Switch: > NHTSA09V399000 >
Oct > 09 > Recall 09V399000: Cruise Control Deactivation Switch
Cruise Control Switch: All Technical Service Bulletins Recall 09V399000: Cruise Control
Deactivation Switch
VEHICLE MAKE/MODEL: MODEL YEAR(S): Ford/Econoline 1992-2003 Ford/Excursion
2000-2003 Ford/Explorer 1995-2002 Ford/F Super Duty 1993-1997 1999-2003 Ford/F53 1994
Ford/Ranger 1995-1997 2001-2003 Ford/Windstar 1995-2003 Mercury/Mountaineer 1995-2002
MANUFACTURER: Ford Motor Company
MFR'S REPORT DATE: October 09, 2009
NHTSA CAMPAIGN ID NUMBER: 09V399000
NHTSA ACTION NUMBER: N/A COMPONENT: Vehicle Speed Control
POTENTIAL NUMBER OF UNITS AFFECTED: 4500000
SUMMARY: Ford is recalling model years 1995-2003 Windstar, 2000-2003 Excursion, 1993-1997
and 1999-2003 F-Super Duty, 1992-2003 Econoline, 1995-2002 Explorer and Mercury
Mountaineer, 1995-1997 and 2001-2003 Ranger, and 1994 F53 vehicles equipped with the Texas
Instruments Speed Control Deactivation Switch (SCDS). The SCDS may leak internally and then
overheat, smoke, or burn.
CONSEQUENCE: A vehicle fire could occur.
REMEDY: Ford will notify owners and dealers will install a fused wiring harness for the SCDS.
Dealers will also inspect the ABS control connector and repair as necessary. Repairs will be
completed free of charge. The safety recall is expected to begin on or about October 26, 2009.
Owners may contact Ford at 1-800-392-3673.
NOTES: Ford's recall campaign number is 09S09. Owners may also contact The National Highway
Traffic Safety Administration's Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or
go to http://www.safercar.gov.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > Page 10988
Cruise Control Switch: Specifications
Speed Control Actuator Switch Screws 6.5-7.5 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Technical Service Bulletins > Page 10989
Cruise Control Switch: Service Precautions
CAUTION: When separating the speed control actuator switch from the steering wheel, it is
necessary to take precautions not to damage the steering wheel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair > Without Remote Audio
Cruise Control Switch: Service and Repair Without Remote Audio
REMOVAL
1. Remove the driver side air bag module. Refer to Air Bag Systems.
2. Remove the speed control actuator switches.
1 Remove the screws.
2 Disconnect the electrical connector then remove the speed control actuator switches.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16km (10
miles) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Service and Repair > Without Remote Audio > Page 10992
Cruise Control Switch: Service and Repair With Remote Audio
REMOVAL
1. Disconnect the battery ground cable.
2. Separate the speed control actuator switch out of the steering wheel.
CAUTION: When separating the speed control actuator switch from the steering wheel, it is
necessary to take precautions not to damage the steering wheel.
3. Remove the speed control actuator switch.
1 Disconnect the speed control actuator switch electrical connector.
2 Remove the speed control actuator switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn its strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Locations > Page 10997
ABS Light: Description and Operation
The Antilock Brake System (ABS) uses the yellow ABS warning indicator to alert the driver of a
malfunctions in the ABS.
The yellow ABS warning indicator will come on to warn the driver that the ABS has been turned off
due to a symptom that exists in the ABS. Normal power assist braking remains but wheels can lock
during a panic stop while the yellow ABS warning indicator is illuminated.
The diagnostic procedures must be followed step-by-step in order to correct the condition.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Conditioning Indicator Lamp >
Component Information > Service and Repair
Air Conditioning Indicator Lamp: Service and Repair
Climate Control Bulb
For additional information, refer to Heating and Air Conditioning.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > Customer Interest: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning
Effort/MIL ON/DTC's Set
Audible Warning Device: Customer Interest Ignition Switch - High Turning Effort/MIL ON/DTC's Set
Article No. 01-21-13
10/29/01
^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039
CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH
EFFORT WHEN TURNING IGNITION SWITCH
^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN
TURNING IGNITION SWITCH
FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001
EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002
SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER
SPORT TRAC
LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER
ISSUE
Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent
conditions:
^ Roughness and/or excessive effort in turning the key from RUN to START position.
^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent
accessory function.
^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes
P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory.
This may be caused by a Key-In-Ignition warning chime switch.
ACTION
Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock
cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Disconnect the battery ground cable and wait at least one minute.
2. Insent the ignition key and turn it to the RUN position.
3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock
cylinder) and press the release button while pulling out the ignition switch lock cylinder.
NOTE
SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD
REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH
LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS
REQUIRED.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > Customer Interest: > 01-21-13 > Oct > 01 > Ignition Switch - High Turning
Effort/MIL ON/DTC's Set > Page 11009
4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while
sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model
Workshop Manual, Key-in-ignition warning switch removal and installation section located in
Section 413 if additional detail is required.
5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder.
6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime
switch.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
012113A Replace The 0.3 Hr.
Key-In-Ignition Warning Chime Switch
DEALER CODING
CONDITION
BASIC PART NO. CODE
11A127 42
OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000,
208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-21-13 > Oct > 01 > Ignition Switch - High
Turning Effort/MIL ON/DTC's Set
Audible Warning Device: All Technical Service Bulletins Ignition Switch - High Turning Effort/MIL
ON/DTC's Set
Article No. 01-21-13
10/29/01
^ DRIVEABILITY - DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039
CONTINENTAL MODELS ONLY - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH
EFFORT WHEN TURNING IGNITION SWITCH
^ ELECTRICAL - STICKING OR BINDING IGNITION LOCK CYLINDER - HIGH EFFORT WHEN
TURNING IGNITION SWITCH
FORD: 1998-2002 CROWN VICTORIA, MUSTANG, TAURUS 1998-1999 F-250 LD 1998-2001
EXPLORER 1998-2002 E SERIES, EXPEDITION, F-150, RANGER, WINDSTAR 1999-2002
SUPER DUTY F SERIES 2000-2002 EXCURSION, EXPLORER SPORT 2001-2002 EXPLORER
SPORT TRAC
LINCOLN: 1998-2002 CONTINENTAL, TOWN CAR, NAVIGATOR 2002 BLACKWOOD
MERCURY: 1998-2002 GRAND MARQUIS, SABLE 1998-2001 MOUNTAINEER
ISSUE
Some ignition switch lock cylinder assemblies may exhibit the following highly intermittent
conditions:
^ Roughness and/or excessive effort in turning the key from RUN to START position.
^ Key does not fully return from START to RUN after starting vehicle. This may result in intermittent
accessory function.
^ Continental ONLY - A malfunction indicator lamp may illuminate with diagnostic trouble codes
P0500, P1502 and UlO3g stored in the Powertrain Control Modules (PCM) memory.
This may be caused by a Key-In-Ignition warning chime switch.
ACTION
Replace the KEY-IN-IGNITION WARNING CHIME SWITCH located on the ignition switch lock
cylinder with revised pant XL2Z-11A127-AB. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
1. Disconnect the battery ground cable and wait at least one minute.
2. Insent the ignition key and turn it to the RUN position.
3. Insert a punch into the access hole (located in the lower steering column shroud, below the lock
cylinder) and press the release button while pulling out the ignition switch lock cylinder.
NOTE
SOME VEHICLES DO NOT HAVE AN ACCESS HOLE AND REQUIRE LOWER SHROUD
REMOVAL. REFER TO THE APPROPRIATE MODEL WORKSHOP MANUAL, IGNITION SWITCH
LOCK CYLINDER REMOVAL AND INSTALLATION SECTION 211 IF ADDITIONAL DETAIL IS
REQUIRED.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Technical Service Bulletins: > 01-21-13 > Oct > 01 > Ignition Switch - High
Turning Effort/MIL ON/DTC's Set > Page 11015
4. Remove the Plastic Key chime warning switch by prying upward on the plastic retainer, while
sliding the switch away from the key insertion end (Figure 1). Refer to the appropriate model
Workshop Manual, Key-in-ignition warning switch removal and installation section located in
Section 413 if additional detail is required.
5. Install a new Key-In-Ignition warning chime switch XL2Z-11A127-AB and reinstall lock cylinder.
6. Verify proper function of the Ignition Switch Lock Cylinder and Key-In-Ignition warning chime
switch.
Parts Block
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
And Emissions Warranty Coverage
OPERATION DESCRIPTION TIME
012113A Replace The 0.3 Hr.
Key-In-Ignition Warning Chime Switch
DEALER CODING
CONDITION
BASIC PART NO. CODE
11A127 42
OASIS CODES: 102000, 112000, 202000, 203000, 204000, 204200, 205000, 206000, 207000,
208000, 208999, 301000, 302000, 497000, 504000, 601300, 603300, 698298
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers
Radio/Stereo Noise Filter: All Technical Service Bulletins Fuel Pump - Whine Heard Through Radio
Speakers
Article No. 01-7-3
04/16/01
^ FUEL SYSTEM - FUEL PUMP "WHINING"/"BUZZING" NOISE COMES THROUGH
ENTERTAINMENT OR TWO - WAY RADIO SPEAKER
^ RADIO - ENTERTAINMENT OR TWO - WAY COMMUNICATION - "WHINING"/"BUZZING"
NOISE IN SPEAKERS CAUSED BY FUEL PUMP
^ NOISE - "WHINING"/"BUZZING" - COMES THROUGH SPEAKERS OF ENTERTAINMENT OR
TWO-WAY RADIO
FORD: 1990-1994
TEMPO
1990-1997 PROBE, THUNDERBIRD
1990-1999 ESCORT, MUSTANG, TAURUS
1990-2001 CROWN VICTORIA
1997-1999 CONTOUR
2001 TAURUS
1990 BRONCO II
1990-1996 BRONCO
1990-1997 AEROSTAR, F SUPER DUTY, F-250 HD, F-350
1990-1999 F-250 LD
1990-2001 ECONOLINE, F-150, RANGER
1991-2001 EXPLORER
1995-2001 WINDSTAR
1997-2001 EXPEDITION
1999-2001 SUPER DUTY F SERIES
2000-2001 EXCURSION
2001 ESCAPE
LINCOLN: 1990-1992
MARK VII
1990-1999 CONTINENTAL
1990-2001 TOWN CAR
1997-1998 MARK VIII
1998-2001 NAVIGATOR
MERCURY: 1990-1994
TOPAZ
1990-1997 COUGAR
1990-1999 SABLE
1990-2001 GRAND MARQUIS
1991-1999 TRACER
1997-1999 MYSTIQUE
1999 COUGAR
2001 SABLE
1993-2001 VILLAGER
1997-2001 MOUNTAINEER
This TSB article is being republished in its entirety to update the model year vehicles.
ISSUE
A "whining"/"buzzing" noise in the speakers of the entertainment radio or two-way radio on vehicles
with an in-tank electric fuel pump may be caused by electrical noise from the fuel pump.
ACTION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11021
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11022
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11023
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11024
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11025
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11026
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11027
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11033
Install an electronic noise Radio Frequency Interference (RFI) Filter (F1PZ-18B925-A) on the fuel
pump inside the fuel tank. Refer to the following Test Procedure to confirm that the concern exists,
then refer to the Service Procedure for repair details.
NOTE
SOME LIGHT TRUCKS REQUIRE ONE (1) RFI FILTER FOR EACH IN-TANK ELECTRIC FUEL
PUMP ON MULTI-TANK VEHICLES.
NOTE
THIS TSB DOES NOT INCLUDE TAURUS FLEXIBLE FUEL VEHICLES (FFVS) OR 1999
RANGER 3.0L FFVS.
TEST PROCEDURE
Fuel pump radio noise is relatively constant and changes only slightly with vehicle speed. If the
frequency of the noise varies or the noise comes and goes with the vehicle speed, then it is not the
fuel pump and this fix will not be effective. The following procedure will help determine if the fuel
pump is the cause of the radio noise:
1. Turn on the radio before the key is turned on (assuming the radio will operate without the ignition
key - you may need to put the ignition key in the Accessory position).
2. Turn the ignition key to the Run position (do not start the engine).
3. The fuel pump should run for about 1 second with the key in the Run position with the engine not
running. Listen for noise in the radio. If noise is present while the pump is running and stops when
the pump stops, then the noise is being generated by the pump and this procedure should help.
SERVICE PROCEDURE
1. Remove the fuel pump sender assembly from the fuel tank. Refer to the appropriate model year
Workshop Manual for removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11034
2. On vehicles without a fuel delivery module, remove the negative and positive connectors from
the fuel pump, Figure 1.
a. Cut the wires to the fuel pump 76 mm (3") from the flange of the fuel pump and discard the
wires.
b. Connect the RFI filter connectors to the spade terminal on the fuel pump.
c. Cut and solder both the red and black wires of the RFI filter to the red and black wires of the
flange. Use Heat Shrink Tubing (F5AZ-14A099-M) over the solder connections.
NOTE
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11035
TUBING (ABOUT 50 mm (2",)) OF THE SPECIFIED TYPE TO ENTIRELY COVER EACH
SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO PREVENT EXPOSURE OF
THE CONNECTIONS.
NOTE
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE GROUND WIRE TO A POINT CLOSE TO THE FUEL
TANK. IF THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM
CORROSION SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE
LITERATURE (EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11036
3. On light trucks and compact trucks with a fuel delivery module, cut the fuel pump wires to the
fuel delivery module 50 mm (2") from the flange and discard the wires, Figure 2.
a. Cut the connectors from the RFI filter and solder wires to the fuel delivery module (red to red and
black to black). Use heat shrink tubing over soldering connections.
b. Solder wires from the RFI filter to the flange wires (red to red and black to black). Use heat
shrink tubing over soldered connections.
NOTE:
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11037
HEAT SHRINK TUBING MUST BE USED OVER ALL SOLDERED CONNECTIONS MADE PRIOR
TO THIS TSB. USE SUFFICIENT TUBING (ABOUT 50 mm (2")) OF THE SPECIFIED TYPE TO
ENTIRELY COVER EACH SOLDERED CONNECTION AND SHRINK APPROPRIATELY TO
PREVENT EXPOSURE OF THE CONNECTIONS.
NOTE:
FOR SOME VEHICLES WITH EXTREMELY LONG FUEL PUMP GROUND WIRE CIRCUITS, IT
MAY BE NECESSARY TO SHORTEN THE WIRE TO A POINT CLOSE TO THE FUEL TANK IF
THE GROUND IS MOVED, BE SURE IT IS SECURE AND PROTECTED FROM CORROSION.
SINCE IT IS THE OPERATING GROUND FOR THE PUMP. CHECK SERVICE LITERATURE
(EVTM, ETC.) FOR GROUND LOCATIONS.
WARNING
ALL SOLDERING AND HEAT SHRINKING MUST BE COMPLETED AWAY FROM THE FUEL
TANK AREA. USE A SOLDERING IRON ONLY FOR SOLDERING AND HEAT GUN ONLY FOR
APPLYING SHRINK TUBING.
4. Secure the RFI filter to the fuel pump and sender assembly with a Bundling Strap (95873-S101)
to prevent rattling in the tank, Figures 1 and 2.
5. Reinstall the fuel pump sender assembly into the fuel tank.
CAUTION
INSTALL NEW GASKETS WHEN REINSTALLING SENDER TO PREVENT LEAKS. REFER TO
THE PARTS CATALOG FOR PROPER APPLICATIONS.
6. Check the appropriate Electrical and vacuum troubleshooting manual (EVTM) (or other Service
Literature) for the location of the fuel pump pump ground. If ground is more than 0.9m (3') from the
tank, cut wire and ground fuel pump end within 0.9m (3') of the tank to prevent ground wire from
acting as an antenna. Be sure ground is secure and protected from corrosion since it is the
operating ground for the fuel pump.
7. Install the fuel tank in the vehicle as outlined in the appropriate Service or Workshop manual.
PARTS BLOCK
OTHER APPLICABLE ARTICLES: 90-18-3, 91-17-5 SUPERSEDES: 99-12-9 WARRANTY
STATUS: Eligible Under The Provisions of Bumper To Bumper Warranty Coverage
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11038
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Audible Warning Device: > 01-7-3 > Apr > 01 >
Fuel Pump - Whine Heard Through Radio Speakers > Page 11039
OPERATION/DESCRIPTION/TIME
DEALER CODING
OASIS CODES: 205000, 207000, 404000, 702000, 702300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions
Audible Warning Device: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11042
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11043
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11044
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11045
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11046
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11047
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11048
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11049
Audible Warning Device: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11050
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11051
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11052
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11053
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11054
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11055
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11056
Audible Warning Device: Electrical Diagrams
Diagram 66-1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11057
Diagram 66-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 11058
Diagram 66-3
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Page 11059
Audible Warning Device: Description and Operation
A short warning chime (0.1 second) is output with every message center switch press. A longer
warning chime (1.0 second) is output when a new warning first appears on the message center
indicator display.
To activate the warning, the message center pulls the chime request output below one volt during
the length of the tone.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Page 11060
Audible Warning Device: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Page 11061
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Audible Warning Device Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11067
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11068
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11069
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11070
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11071
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11072
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11073
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11074
Audible Warning Device Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11075
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11076
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11077
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11078
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11079
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11080
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Page 11081
Audible Warning Device Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Page 11082
Audible Warning Device Control Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module >
Component Information > Diagrams > Page 11083
Audible Warning Device Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Locations > Page 11087
Brake Warning Indicator: Description and Operation
Brake System
The red brake warning light (BRAKE) is used to indicate a low fluid level, brake malfunction or a
parking brake that is not fully released. The brake fluid level switch is located in the brake fluid
reservoir.
The yellow brake warning indicator is used to indicate a malfunction or deactivation of the Anti-lock
Brake System (ABS). It illuminates when triggered by the ABS control module and stays illuminated
as long as the malfunction remains in the system.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component
Information > Description and Operation > Instrument Cluster
Charge Lamp/Indicator: Description and Operation Instrument Cluster
The charge system warning indicator illuminates when there is no generator (GEN) output.
When the ignition switch contacts are closed, battery current flows through the charge indicator and
the parallel resistor (390 ohm) to the voltage indicator, and the indicator illuminates.
When the generator builds up enough voltage to energize a circuit in the voltage regulator, the
indicator goes out.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component
Information > Description and Operation > Instrument Cluster > Page 11093
Charge Lamp/Indicator: Description and Operation Information and Message Center
This warning message is displayed when the electrical system is not maintaining correct voltage at
the message center indicator. There will be a few seconds delay before the warning is displayed or
removed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Check Gauges Lamp > Component
Information > Locations > Page 11097
Check Gauges Lamp: Description and Operation
The CHECK GAGE indicator will illuminate if any of the following occur:
- Engine oil pressure drops below approximately 42 kPa (6 psi).
- Fuel level drops below approximately 4-8 L (1-2 gal).
- Engine temperature exceeds approximately 121°C (250°F).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions
Cigarette Lighter: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 11103
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 11104
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 11105
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 11106
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 11107
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 11108
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 11109
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information
> Diagrams > Diagram Information and Instructions > Page 11110
Cigarette Lighter: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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> Diagrams > Diagram Information and Instructions > Page 11111
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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> Diagrams > Diagram Information and Instructions > Page 11112
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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> Diagrams > Diagram Information and Instructions > Page 11113
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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> Diagrams > Diagram Information and Instructions > Page 11114
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> Diagrams > Diagram Information and Instructions > Page 11115
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> Diagrams > Diagram Information and Instructions > Page 11116
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> Diagrams > Diagram Information and Instructions > Page 11117
Diagram 44-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Locations
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Locations > Page 11121
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Locations > Page 11122
Compass: Service Precautions
CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a
cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth
covers the front third and the entire width of the roof.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Locations > Page 11123
Compass: Description and Operation
A compass and outside temperature display are contained in the overhead console. The compass
and temperature display can be turned off and on by pressing the MODE switch in the overhead
console. The vehicle heading is displayed as one of N, NE, E, SE, S, SW, W, and NW.
Compass Accuracy
Magnetic mounted devices like antennas and luggage racks should not be located on the front third
of the vehicle roof. Placing these devices near the compass will cause inaccurate directional
readings. If these devices must be used, accuracy may be improved by recalibrating the compass
while the devices are installed on the vehicle.
Driving near power lines, or driving in the area of large iron or steel structures can temporarily
change the compass heading. If the compass remains inaccurate after driving near such objects,
demagnetize the vehicle and recalibrate the compass.
Most geographic areas (zones) have a magnetic north compass point that varies slightly from the
northerly direction on maps. This variation is four degrees between the adjacent zones and will
become noticeable as the vehicle crosses multiple zones. A correct zone setting eliminates the
error. Refer to Compass Zone Adjustment. See: Adjustments/Compass Zone Adjustment
Temperature, Outside Air
The thermometer sensor is attached to the radiator frame behind the grille. The temperature can be
displayed in centigrade or Fahrenheit by pressing the MODE switch.
If the outside temperature falls below 3.3°C (38°F), the display will alternate from "ICE" to the
outside temperature at a two second rate for one minute.
The outside air temperature reading can be affected by engine heat when the vehicle is idling or
has been off for less than two hours. The compass and thermometer will limit the increase of the
displayed temperature to one degree per minute at very low speeds or immediately after the
ignition is turned on. After two minutes at a sustained speed of at least 53 km/h (33 mph), effects of
engine heat are minimal and the compass will display the current outside temperature reading.
Temperature decreases are always updated immediately.
If the outside air temperature sensor is short or open circuited, then the display will show 60°C
(140°F) or -40°C (-40°F) respectively in place of temperature.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview
Compass: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the compass and thermometer. 2. Visually inspect for
obvious signs of mechanical and electrical damage.
VISUAL INSPECTION CHART
3. If inspection reveals an obvious concern(s) that can be readily identified, repair or replace as
required. 4. If the fault is not visually evident, determine the symptom and proceed to Symptom
Chart. See: Symptom Related Diagnostic Procedures
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11126
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11127
Compass: Pinpoint Tests
Connector Circuit Reference
Refer to the Vehicle/Diagrams for schematic and connector information.
Pinpoint Test Notes
NOTE:
- Always set the zone, calibrate, and demagnetize a vehicle before replacing an inaccurate
compass.
- After replacing the compass, always set the zone and calibrate.
Test A: Compass Is Inaccurate/Inoperative
A1 - A2
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11128
A3 - A4
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11129
A5 - A6
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11130
A7 - A8
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11131
A9 - A10
Test B: Outside Air Temperature Is Inaccurate/Inoperative
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11132
B1 - B2
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11133
B3 - B4
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11134
B5 - B6
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Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11135
Special Service Tool(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Adjustments > Compass Zone Adjustment
Compass: Adjustments Compass Zone Adjustment
1. Determine the zone in which the vehicle is located. 2. Press and hold the MODE button until
VAR appears on the display. Release the MODE button. 3. Momentarily press the MODE button to
increment the zone by one. Set the zone according to the map.
NOTE: After a few seconds, the compass will exit the VAR mode if the button is no longer pressed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Adjustments > Compass Zone Adjustment > Page 11138
Compass: Adjustments Calibration Adjustment
1. Start the vehicle.
NOTE: For optimum calibration, drive to an open, level location away from large metallic objects or
structures. Switch off all non-essential electrical accessories (rear window defrost, heater A/C, map
lamps, wipers, etc.) and make sure all doors are closed.
2. Locate the electronic compass/temperature display on the overhead console, press and hold the
MODE button until CAL appears in the display,
then release the MODE button.
NOTE: To exit CAL mode before performing a compass adjustment, turn the ignition switch to the
OFF position.
3. Drive the vehicle slowly (less than 5 km/h [3 mph]) in complete circles until CAL disappears from
the display.
NOTE: If the CAL indicator does not turn off after the vehicle has been driven in a circle no more
than five times, demagnetize the vehicle and repeat the procedure.
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Adjustments > Compass Zone Adjustment > Page 11139
Compass: Adjustments Vehicle Demagnetizing
CAUTION: During demagnetizing, the demagnetizer coil will be pulled toward the vehicle. Place a
cloth over the vehicle roof to protect the vehicle surface if contact occurs. Make sure the cloth
covers the front third and the entire width of the roof.
NOTE:
- The demagnetizing process requires the use of a demagnetizing coil commonly used by television
repair technicians to demagnetize television tubes.
- To demagnetize, use a constant circular motion over the vehicle roof. Do not turn off the
demagnetizer while sweeping the vehicle roof to prevent remagnetizing ferrous materials contained
in the vehicle.
- During the demagnetizing process, make sure the phenolic surface of the tool (the side opposite
the handle) is closest to the vehicle surface.
1. Demagnetize the front third of the vehicle roof.
1 Turn on the demagnetizer at least 1 m (3 ft) away from the vehicle.
2 Holding the demagnetizer no more than 2.5 cm (1 in) from the vehicle roof and starting on the
passenger side, demagnetize the front third of the vehicle roof closest to the windshield using a
constant circular motion. Keep the circle radius within 30 cm (12 in) while sweeping across the
entire surface of the vehicle roof closest to the windshield. Continue the circular motion four times.
3 After the fourth pass and without stopping, move the demagnetizer at least 1 m (3 ft) away from
the vehicle.
4 Turn the demagnetizer off.
2. Perform the Compass Zone Adjustment procedure. See: Compass Zone Adjustment 3. Perform
the Compass Calibration Adjustment procedure. See: Calibration Adjustment
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Adjustments > Page 11140
Compass: Service and Repair
REMOVAL
1. Remove the overhead console; refer to Interior Trim.
2. Remove the screws and disconnect the electrical connector.
3. Remove the compass/lamp bezel from the console housing.
1 Push the clip.
2 Remove the compass/lamp bezel from the console housing.
4. Remove the compass and thermometer.
1 Push the three locking tabs.
2 Remove the compass and thermometer.
INSTALLATION
1. To install, reverse the removal procedure.
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Adjustments > Page 11141
Special Service Tool(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cruise Control Indicator Lamp >
Component Information > Locations > Page 11145
Cruise Control Indicator Lamp: Description and Operation
The Speed Control Indicator (SPEED CONT) lamp will illuminate when the speed control is
engaged.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
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Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11151
7. Remove the two steering wheel back cover plugs.
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
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Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11152
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11153
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11154
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11155
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11156
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Prove out the system means to turn the ignition switch from the OFF to the RUN position and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately six seconds and then turn off. If an air bag Supplemental
Restraint System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Service and Repair
Dimmer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information >
Service and Repair > Page 11160
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp >
Component Information > Locations > Page 11164
Door/Trunk Ajar Indicator/Lamp: Description and Operation
The DOOR AJAR indicator illuminates when any of the vehicle doors are open.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information >
Locations > Page 11168
Door Switch: Service and Repair
REMOVAL
1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door
Latch.
3. Remove the door opening warning lamp switch.
1 Lift the locking tab.
2 Rotate the door opening warning lamp switch counterclockwise.
3 Remove the door opening warning lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions
Driver/Vehicle Information Display: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11173
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11174
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11175
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11176
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11177
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11178
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11179
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11180
Driver/Vehicle Information Display: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11181
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11182
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11183
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11184
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11185
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11186
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11187
Driver/Vehicle Information Display: Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11188
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11189
Driver/Vehicle Information Display: Electrical Diagrams
Diagram 69-1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 11190
Diagram 69-2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation > System Description
Driver/Vehicle Information Display: Description and Operation System Description
The message center system consists of:
- message center switch module
- message center indicator
Message Center Switch Module The message center switch module has seven switches and is
located below the message center indicator in the center console. The message center switches
are: ENGLISH/METRIC mode
- fuel computer (FUEL) RANGE
- STATUS
- economy (ECON)
- RESET
- system check and warnings (SYSTEM CHECK)
- OIL CHANGE RESET
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation > System Description > Page 11193
Driver/Vehicle Information Display: Description and Operation Principles of Operation (How Does It
Work ?)
Display Dimming
The dimming of the indicator display is controlled by the pulse width dimmer module. The voltage
on Pin 2 controls the brightness of the message center display. When the exterior lamps are off,
this voltage will be zero volts and the message center display will be at maximum brightness. When
the exterior lamps are on, this voltage will be controlled by the pulse width dimmer module and will
be between 2.5 volts and battery voltage. The message center display will be brighter as this
voltage approaches battery voltage. If there is a warning on the message center display, the
display will not dim to its lowest level.
When the headlamps or parking lamps are OFF, the display of the message center indicator will be
maximum brightness and the labels for the center five switches of the message center switch
module will not be illuminated.
When the head lamps or parking lamps are ON, the brightness of the display of the message
center indicator and the labels for the center five switches of the message center switch module will
be controlled by the pulse width dimmer module.
English/Metric Mode
The ENGLISH/METRIC switch controls the display mode for both the message center indicator and
the electronic automatic temperature control. A press of the ENGLISH/METRIC switch will change
both displays between english mode and metric mode.
Vehicle Speed Signal
The vehicle speed signal is generated by the rear anti-lock brake sensor and sent to the 4-wheel
Anti-lock Brake System (4WABS) module. The 4WABS module sends the vehicle speed signal via
circuit 679 (GY/BK) to all systems which require a vehicle speed signal input.
Fuel Computer - Range
The RANGE feature has two displays: the distance that can be traveled before refueling, and the
distance that was traveled since the last trip odometer reset. The RANGE switch will change the
message center indicator between the two displays.
The RANGE (distance to empty) feature is calculated using the fuel flow signal from the Powertrain
Control Module (PCM), the speed signal from the 4WABS module and the fuel level signal from the
fuel level sender.
The fuel flow and speed signals are used to calculate a Running Average Fuel Economy (RAFE),
which is multiplied by the fuel remaining to give the range.
RAFE is not the same number as the Average Fuel Economy displayed by the message center
indicator.
RAFE is based on the past driving history and can only be reset by disconnecting the battery.
When the range decreases to 80 km (50 mile) to empty, the message center will display the LOW
FUEL LEVEL warning.
With a fuel tank full of fuel (160 ohm signal from fuel sender) and after a battery disconnect, the
RANGE should be approximately 644 km (400 miles) to empty.
The RANGE (trip odometer) feature is calculated using the speed signal from the 4WABS module.
It can be reset to zero by pressing the reset switch while the trip odometer is displayed on the
message center.
Fuel Computer - Status
The STATUS feature has two displays: Fuel-to-Empty and Fuel-Used. The STATUS switch will
change the message center indicator between the two displays.
The fuel-to-empty calculation is achieved using the fuel level signal from the fuel level sender.
The fuel-used feature is calculated using the fuel flow signal from the PCM and can be reset to
zero by pressing the RESET switch while the fuel-used feature is displayed on the message center.
Fuel Computer - Economy
The Economy (ECON) feature has two displays: average and instant.
Depressing the ECON switch changes the message center indicator between both displays.
The economy is calculated using the fuel flow signal from the powertrain control module and the
speed signal from the 4WABS module.
The average fuel economy feature can be reset by pressing the RESET switch while the average
fuel economy feature is displayed on the message center indicator.
System Check and Warnings
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation > System Description > Page 11194
The SYSTEM CHECK feature cycles the message center indicator through a status of each system
being monitored. For each of the monitored systems, the message center indicator will indicate either an OK
message or a warning message for two seconds.
- At normal conclusion of the system check sequence, the message center indicator will display all
active warnings or the last feature displayed before entering the SYSTEM CHECK mode.
- System warnings alert the driver to possible concerns or malfunctions in the vehicle operating
systems.
- There are 7 warning messages which can be displayed for two seconds by the message center
indicator to show the status of the monitored systems.
- When a warning occurs, the warning message is displayed and a one-second tone sounds. The
warning message will appear at a brighter level if the message center indicator is dimmed.
- In the event of a multiple warning situation, the message center indicator will cycle the display to
show all warnings by displaying each warning message for four seconds.
- To display the operator selectable features of the message center indicator while a warning is
displayed, the warning message may be removed from the message center indicator display by
pressing the RESET switch. The message center indicator will display the last selected feature if
there are no more warning messages.
- This allows operation of all functions of the message center indicator after pressing the RESET
switch and clearing the warning message.
Warning messages which have been reset will either reappear on the display in 10 minutes from
the reset or will not reappear until an ignition switch OFF-RUN cycle.
If warning messages reappear it is a reminder that these warning conditions still exist. Warnings
may be repeatedly reset. All warning messages will reappear after an entire SYSTEM CHECK
sequence has been completed.
Charging System Warning (CHECK CHARGING SYSTEM)
This warning message is displayed when the electrical system is not maintaining correct voltage at
the message center indicator. There will be a few seconds delay before the warning is displayed or
removed.
Engine Coolant Temperature Warning (CHECK ENGINE TEMP)
This warning message is displayed when the engine coolant is overheating.
The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message
center indicator).
If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be
no warning. If it is less than approximately 2.7 volts, at a battery voltage of 13.5 volts then the
warning will be displayed.
The message center indicator filters this input; therefore, there will be a few seconds delay before
the warning is displayed or removed.
Fuel Level Warning (LOW FUEL LEVEL)
This warning message is displayed when there is approximately 80 km (50 mile) or less left before
the vehicle runs out of fuel.
Oil Level Warning (LOW OIL LEVEL)
This warning message is displayed when the engine oil level is low.
When the engine oil level is normal, the input to the message center indicator will be an open
circuit.
When the engine oil level is low, the low oil level sensor will close, grounding the input to the
message center indicator and the warning will be displayed during the next ignition cycle of OFF to
RUN. This low oil level sensor is only monitored when the ignition switch is OFF.
There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the
oil pan and reach the correct level.
Oil Life Warning (CHANGE OIL SOON or OIL CHANGE REQUIRED)
If the connection to the oil temperature sensor is open circuit or shorted, the message center
display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE
LEFT during system cheek sequence.
One of these warning messages is displayed when the engine oil life remaining is five percent or
less. When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message will
be displayed.
- When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be
displayed.
The message center indicator will indicate the percent of oil life remaining during System Check.
This percentage is based on the driving history and the time since the last oil change. In order to
ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET
procedure, as described in the Owner's Guide, after an oil change.
To calculate the percentage of oil life remaining, the oil life feature uses: oil temperature sensor input
- tachometer input from the PCM
- vehicle speed signal input
- clock time (maintained internally by the message center)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation > System Description > Page 11195
- The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or
6 months. It will reach zero percent sooner under different driving conditions.
- The percentage of oil life remaining is the second display in the system check sequence.
- When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON"
message will be displayed.
- When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be
displayed.
Washer Fluid Level Warning (LOW WASHER FLUID)
This warning message is displayed when there is less than one quarter of the container of washer
fluid remaining When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will close,
grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator.
- When the washer fluid level is low, the input to the message center indicator will be open and the
warning will be displayed.
The message center indicator filters this input therefore, there will be a 20-second delay before the
warning is displayed or removed.
Warning Chime
A short warning chime (0.1 second) is output with every message center switch press. A longer
warning chime (1.0 second) is output when a new warning first appears on the message center
indicator display.
To activate the warning, the message center pulls the chime request output below one volt during
the length of the tone.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Description and Operation > Page 11196
Driver/Vehicle Information Display: Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is part of,
please refer to Instrument Panel, Gauges and Warning indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Message Center Assembly
Driver/Vehicle Information Display: Service and Repair Message Center Assembly
REMOVAL
1. Remove the message center console. Grasp the front of the console and lift upward.
2. Disconnect the electrical connectors from the message center indicator.
3. Remove the screws retaining the message center indicator.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Message Center Assembly > Page 11199
Driver/Vehicle Information Display: Service and Repair Message Center Assembly Switch
REMOVAL
1. Remove the message center indicator. Refer to Driver/Vehicle Information Display.
2. Disconnect the electrical connector.
3. Remove the message center switch module screws and remove the module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Page 11200
73 Digital Multimeter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Four Wheel Drive Indicator Lamp >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module >
Component Information > Description and Operation
Fuel Gauge Module: Description and Operation
NOTE:
- The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge
and instrument cluster gauge amplifier are calibrated together.
- If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication
may result. The ignition key must be placed in the OFF position during or after refueling for
accurate fuel gauge indication.
The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge
displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also
supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine
coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board
located in a pocket on the back of the instrument cluster. The electrical connections are made with
a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and
the instrument cluster gauge amplifier must be replaced as a unit.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module >
Component Information > Description and Operation > Page 11208
Fuel Gauge Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Fuel Gauge Module >
Component Information > Description and Operation > Page 11209
Fuel Gauge Module: Service and Repair
Service and Repair
The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and
must be replaced as a set.
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Testing and Inspection
Fuel Gauge Sender: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Testing and Inspection > Page 11213
Fuel Gauge Sender: Service and Repair
Service and Repair
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming and Arming
Supplemental Restraint System (SRS) Deactivation and Reactivation Deactivation Procedure
WARNING: Always wear safety glasses when repairing an air bag supplemental restraint system
(SRS) vehicle and when handling an air bag module. This will reduce the risk of injury in the event
of an accidental deployment.
WARNING: Carry a live air bag module with the air bag and trim cover pointed away from your
body. This will reduce the risk of injury in the event of an accidental deployment.
WARNING: Do not set a live air bag module down with the trim cover face down. This will reduce
the risk of injury in the event of an accidental deployment.
WARNING: After deployment, the air bag surface can contain deposits of sodium hydroxide, a
product of the gas generant combustion that is irritating to the skin. Wash your hands with soap
and water afterwards.
WARNING: Air bag modules with discolored or damaged trim covers must be replaced, not
repainted.
WARNING: Never probe the connectors on the air bag module. Doing so can result in air bag
deployment, which can result in personal injury.
WARNING:To reduce the risk of personal injury, do not use any memory saver devices.
NOTE: If a seat equipped with a seat mounted side air bag and/or a safety belt pretensioner (if
equipped) system is being serviced, the supplemental restraint system (SRS) must be depowered.
NOTE: The air bag warning lamp illuminates when the RCM fuse is removed and the ignition
switch is ON. This is normal operation and does not indicate a supplemental restraint system
(SRS) fault.
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the
customer.
All vehicles
1. Turn all vehicle accessories OFF. 2. Turn the ignition switch to OFF. 3. At the central junction
box (CJB), located on the LH end of the instrument panel, open the kick panel cover and remove
the restraints control
module (RCM) fuse F2 (7.5A) from the CJB. For additional information, refer to the Wiring Diagram
See: Restraint Systems/Air Bag Systems.
4. Turn the ignition ON and visually monitor the air bag indicator for at least 30 seconds. The air
bag indicator will remain lit continuously (no
flashing) if the correct RCM fuse has been removed. If the air bag indicator does not remain lit
continuously, remove the correct RCM fuse before proceeding.
5. Turn the ignition OFF.
6. WARNING: To avoid accidental deployment and possible personal injury, the backup power
supply must be depleted before repairing or
replacing any front or side air bag supplemental restraint system (SRS) components and before
servicing, replacing, adjusting or striking components near the front or side air bag sensors, such
as doors, instrument panel, console, door latches, strikers, seats and hood latches. The first row
side impact sensors (if equipped) are located at or near the base of the B-pillars. To deplete the
backup power supply energy, disconnect the battery ground cable and wait at least one minute. Be
sure to disconnect auxiliary batteries and power supplies (if equipped).
Disconnect the battery ground cable (14301) and wait at least one minute. For additional
information, refer to See: Starting and Charging/Battery.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11219
7. Remove the two steering wheel back cover plugs.
8. Remove the two driver air bag module retaining bolts.
9. Remove the driver air bag module.
1. Disconnect the driver air bag module electrical connector. 2. Remove the driver air bag module.
10. Connect the restraint system diagnostic tool 418-F088 to the driver air bag module electrical
connector at the clockspring.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11220
11. Open the glove compartment door to access the passenger air bag module mounting screws.
12. Remove the two screws.
13. CAUTION: Do not handle the passenger air bag module by grabbing the edges of the
deployment door.
Reaching one hand into the glove box opening, push out on the passenger air bag module and
separate it from the instrument panel.
14. Disconnect the electrical connector and remove the passenger air bag module.
15. Connect the restraint system diagnostic tool 418-F088 to the body harness side of the
passenger air bag module electrical connector.
Vehicles equipped with seat side air bags
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11221
16. Disconnect the passenger seat side air bag module electrical connector located under the
passenger seat. 17. Connect the restraint system diagnostic tool 418-133 to the body harness side
of the passenger seat side air bag module electrical connector. 18. Disconnect the driver seat side
air bag module electrical connector located under the driver seat. 19. Connect the restraint system
diagnostic tool 418-133 to the body harness side of the driver seat side air bag module electrical
connector.
All vehicles
20. Install the RCM fuse F2 (7.5A) to the CJB and close the cover. 21. Connect the battery ground
cable.
Reactivation Procedure
All vehicles
1. Remove the RCM fuse F2 (7.5A) from the CJB and close the cover. 2. Disconnect the battery
ground cable and wait at least one minute.
Vehicles equipped with seat side air bags
3. Disconnect the restraint system diagnostic tool from the body harness side of the driver seat side
air bag module electrical connector located under
the driver seat.
4. Connect the driver seat side air bag module electrical connector. 5. Disconnect the restraint
system diagnostic tool from the body harness side of the passenger seat side air bag module
electrical connector located
under the passenger seat.
6. Connect the passenger seat side air bag module electrical connector
All vehicles
7. Disconnect the restraint system diagnostic tool from the body harness side of the passenger air
bag module electrical connector.
8. Install the passenger air bag module.
9. Connect the passenger air bag module electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11222
10. Disconnect the restraint system diagnostic tool from the driver air bag module electrical
connector at the clockspring.
11. Position the driver air bag module to the steering wheel.
1. Connect the driver air bag module electrical connector. 2. Align and position the driver air bag
module to the steering wheel.
12. Install the two driver air bag module retaining bolts.
13. Install the two steering wheel back cover plugs. 14. Turn the ignition switch from OFF to ON.
15. Install the RCM fuse F2 (7.5A) to the CJB and close the cover.
16. WARNING: Be sure that nobody is in the vehicle and that there is nothing blocking or set in
front of any air bag module when the
battery ground cable is connected.
Connect the battery ground cable.
17. Prove out the supplemental restraint system (SRS) as follows:
Turn the ignition key from ON to OFF. Wait 10 seconds, then turn the key back to ON and visually
monitor the air bag indicator with the air bag modules installed. The air bag indicator will light
continuously for approximately six seconds and then turn off. If an air bag supplemental
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the ON position. This is the time required for the restraints control module
(RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and a SRS fault
exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag indicator
and any SRS fault discovered must be diagnosed and repaired.
Clear all continuous DTCs from the restraints control module using a scan tool.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11223
Air Bag(s) Arming and Disarming: Service and Repair Air Bag System Reconnect Checklist
The checklist below should be completed following diagnosis or repair of any air bag system
concern:
1. Is the three-way connector at the base of the steering column connected? 2. Are the air bag
modules connected? 3. Is the Restraints Control Module (RCM) connected? 4. Is the vehicle
battery connected?
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming and Arming > Page 11224
Air Bag(s) Arming and Disarming: Service and Repair Prove Out Procedure
Prove out the system means to turn the ignition switch from the OFF to the RUN position and
visually monitor the air bag indicator with the air bag modules installed. The air bag indicator will
light continuously for approximately six seconds and then turn off. If an air bag Supplemental
Restraint System (SRS) fault is present, the air bag indicator will either:
^ fail to light.
^ remain lit continuously.
^ flash.
The flashing might not occur until approximately 30 seconds after the ignition switch has been
turned from the OFF to the RUN position. This is the time required for the Restraints Control
Module (RCM) to complete the testing of the SRS. If the air bag indicator is inoperative and an
SRS fault exists, a chime will sound in a pattern of five sets of five beeps. If this occurs, the air bag
indicator will need to be repaired before diagnosis can continue.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Bulb > Map Lamp > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Description and Operation
Instrument Panel Circuit Board: Description and Operation
The instrument cluster printed circuit is a flexible circuit that supplies power and ground to the
instrument cluster indicators and gauges. It is constructed of copper foil bonded to a polyester base
film (usually referred to as Mylar).
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Description and Operation > Page 11232
Instrument Panel Circuit Board: Service and Repair
REMOVAL
WARNING: ILLUMINATION BULBS ARE PRESSURIZED AND MAY SHATTER IF IMPROPERLY
HANDLED. WEAR EYE PROTECTION WHEN REPLACING ILLUMINATION BULBS.
CAUTION: If gauges are being removed from the cluster assembly, do not remove the gauge
pointers. Magnetic gauges cannot be recalibrated.
1. Remove the instrument cluster; refer to Instrument Panel. 2. Remove the illumination and
indicator bulbs; refer to Warning Indicator Bulb. 3. Remove the gauges; refer to Gauges.
4. Remove the nineteen instrument gauge clips.
NOTE: Do not reuse instrument gauge clips.
5. Remove the instrument cluster printed circuit.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Locations > Page 11236
Instrument Panel Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Locations > Page 11237
Instrument Panel Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Control Module > Component Information > Locations > Page 11238
Instrument Panel Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel
Illumination Control Module > Component Information > Locations
Panel Illumination Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel
Illumination Control Module > Component Information > Locations > Page 11242
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel
Illumination Control Module > Component Information > Locations > Page 11243
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel
Illumination Control Module > Component Information > Locations > Page 11244
Panel Illumination Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel
Illumination Control Module > Component Information > Locations > Page 11245
Panel Illumination Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Panel
Illumination Control Module > Component Information > Locations > Page 11246
Panel Illumination Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component
Information > Service and Repair
Key Reminder Switch: Service and Repair
For further information regarding the service of this component and the system that it is part of,
please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning
Devices.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component
Information > Description and Operation > Instrument Cluster
Low Fuel Lamp/Indicator: Description and Operation Instrument Cluster
NOTE:
- The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge
and instrument cluster gauge amplifier are calibrated together.
- If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication
may result. The ignition key must be placed in the OFF position during or after refueling for
accurate fuel gauge indication.
The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge
displays the actual fuel level and not the fluctuations due to fuel sloshing. When the fuel level drops
to a predetermined level, the CHECK GAGE indicator will illuminate. The amplifier also supplies the
signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine coolant
temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board located
in a pocket on the back of the instrument cluster. The electrical connections are made with a
spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and
the instrument cluster gauge amplifier must be replaced as a unit.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component
Information > Description and Operation > Instrument Cluster > Page 11254
Low Fuel Lamp/Indicator: Description and Operation Information and Message Center
This warning message is displayed when there is approximately 80 km (50 miles) or less left before
the vehicle runs out of fuel.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Low Fuel Lamp/Indicator > Component
Information > Description and Operation > Page 11255
Low Fuel Lamp/Indicator: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component
Information > Locations > Page 11259
Malfunction Indicator Lamp: Description and Operation
MALFUNCTION INDICATOR LAMP (MIL)
Malfunction Indicator Lamp (MIL)
Check Engine, Service Engine Soon Or ISO Standard Engine Symbol
The Malfunction Indicator Lamp (MIL) (Figure 15) alerts the driver that the Powertrain Control
Module (PCM) has detected an OBD II emission-related component or system fault. When this
occurs, an OBD II Diagnostic Trouble Code (DTC) will be set.
^ The MIL is located on the instrument cluster and is labeled CHECK ENGINE, SERVICE ENGINE
SOON or ISO standard engine symbol (Figure 16).
^ Power is supplied to the MIL whenever the ignition switch is in the RUN or START position.
^ The MIL will remain on in the RUN/START mode as a bulb check during the instrument cluster
proveout for approximately 4 seconds.
^ If the MIL remains on after the bulb check: The PCM illuminates the MIL for an emission related concern and a DTC will be present.
- The instrument cluster will illuminate the MIL if the PCM does not send a control message to the
instrument cluster.
- The PCM is operating in the Hardware Limited Operation Strategy (HLOS).
- The MIL circuit is shorted to ground.
^ If the MIL remains off (during the bulb check): Bulb is damaged.
- MIL circuit is open.
^ To turn off the MIL after a repair, a reset command from the Scan Tool must be sent, or three
consecutive drive cycles must be completed without a fault.
^ For any MIL concern, GO to Computers and Control Systems/Testing and Inspection.
^ If the MIL blinks at a steady rate, a severe misfire condition could possibly exist.
^ If the MIL blinks erratically, an intermittent open B+ to the bulb or an intermittent short to ground
in the MIL circuit exist. Also, the PCM can reset while cranking if battery voltage is low.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Description and Operation
Odometer: Description and Operation
A million-mile tamper-resistant odometer is standard. Replacement speedometers have an
odometer that can be reset to indicate correct vehicle mileage.
NOTE: Some state laws require that the odometer in any replacement speedometer must register
the same as on the removed odometer. Replacement speedometers and odometer modules with
the mileage preset are available through Ford electronic repair centers.
If the actual vehicle mileage cannot be determined, the repair centers are able to supply odometers
set to "0" miles. An odometer mileage sticker is supplied with the replacement odometer. This
sticker must display the estimated vehicle mileage and be affixed to the driver door jamb.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Description and Operation > Page 11263
Odometer: Testing and Inspection
To test the odometer accuracy, drive the vehicle over a measured distance of at least 16
consecutive kilometers (10 mile). Check measured distance against odometer measured distance.
Acceptable odometer measured distance is 15.5 - 16.7 km (9.6 - 10.4 mile).
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Description and Operation
Oil Change Reminder Lamp: Description and Operation
If the connection to the oil temperature sensor is open circuit or shorted, the message center
display will read OIL TEMP SIGNAL ERROR instead of displaying the PERCENTAGE OIL LIFE
LEFT during system cheek sequence.
One of these warning messages is displayed when the engine oil life remaining is five percent or
less.
- When oil life left is between five percent and zero percent, the "CHANGE OIL SOON" message
will be displayed.
- When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be
displayed.
The message center indicator will indicate the percent of oil life remaining during System Check.
This percentage is based on the driving history and the time since the last oil change. In order to
ensure accurate oil life left indications, the driver should only carry out the OIL CHANGE RESET
procedure, as described in the Owner's Guide, after an oil change.
To calculate the percentage of oil life remaining, the oil life feature uses:
- oil temperature sensor input
- tachometer input from the PCM
- vehicle speed signal input
- clock time (maintained internally by the message center)
- The oil life will decrease from 100 percent to 0 percent in no more than 12,070 km (7,500 mile) or
6 months. It will reach zero percent sooner under different driving conditions.
- The percentage of oil life remaining is the second display in the system check sequence.
- When oil life remaining is between five percent and zero percent, the "CHANGE OIL SOON"
message will be displayed.
- When oil life left reaches zero percent, the "OIL CHANGE REQUIRED" message will be
displayed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Description and Operation > Page 11267
Oil Change Reminder Lamp: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component
Information > Description and Operation > Page 11268
Oil Change Reminder Lamp: Service and Repair
Oil Change Reset
Press the OIL CHANGE RESET control to reset the oil life feature to 100% (or your personalized
oil reset percentage) (at optimal driving conditions, 100% oil life is equivalent to a maximum of
12,000 kilometers [7,500 miles]). After you have the oil changed, you must press and hold the OIL
CHANGE RESET control for five seconds. The message center will count down for five seconds.
After a successful reset, the message center will display OIL LIFE RESET TO 100%. (If you have
established a personalized oil reset percentage, the display will show that percentage instead of
100%.) This reset procedure should be performed only after an oil change to ensure accurate oil
life indications.
Your personalized oil reset percentage allows you to establish a smaller oil change interval than
the manufacturer's recommended interval. To establish your personalized oil reset percentage:
1. Press and hold the OIL CHANGE RESET control and press the RESET control while the display
is still counting gown the five seconds to
reset. The display will change to START OIL LIFE AT XXX%.
2. Press the OIL CHANGE RESET control until the displayed percentage is the personalized oil
reset percentage you desire. Your choices are
100%, 90%, 80%, 70%, 60%, 50% 40% and 30%.
3. Press the RESET control to complete the procedure. Pressing any control other than RESET of
OIL CHANGE RESET will abort this
procedure and will not establish your new personalized oil reset percentage.
When your personalized oil reset percentage has been established, it will be used beginning with
the completion of your next OIL CHANGE RESET procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component
Information > Description and Operation
Oil Level Warning Indicator: Description and Operation
This warning message is displayed when the engine oil level is low.
When the engine oil level is normal, the input to the message center indicator will be an open
circuit.
When the engine oil level is low, the low oil level sensor will close, grounding the input to the
message center indicator and the warning will be displayed during the next ignition cycle of OFF to
RUN. This low oil level sensor is only monitored when the ignition switch is OFF.
There is a delay of up to 12 minutes in this monitoring in order to allow the oil to drain back into the
oil pan and reach the correct level.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component
Information > Locations > Page 11275
Oil Pressure Gauge: Testing and Inspection
Magnetic Gauge Testing
The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster
magnetic gauges.
To test the magnetic gauges:
^ Disconnect the connector from the appropriate sender and connect the signal wire to the
Instrument Gauge System Tester.
^ Turn the vehicle ignition switch lock cylinder to the ON position.
With Instrument Gauge System Tester attached to the oil pressure switch connector and the
ignition switch lock cylinder in the RUN position (engine not running), set Instrument Gauge System
Tester to infinite resistance. The center line of the pointer should fall on or below the "L" mark.
Short the connector directly to engine ground. The centerline of the pointer should fall slightly
above mid-scale.
^ If the oil pressure gauge tests within calibration, install a new oil pressure switch.
^ If the oil pressure gauge still tests out of calibration, install a new gauge.
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Specifications
Oil Pressure Sender: Specifications
Oil pressure sensor 9-11 ft.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Specifications > Page 11279
Oil Pressure Sender: Description and Operation
The oil pressure switch is installed in the engine block and consists of a diaphragm and contact
points. The contact points are closed with oil pressure causing the gauge to indicate NORMAL oil
pressure. With no oil pressure, the contacts open and the gauge indicates low oil pressure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Specifications > Page 11280
Oil Pressure Sender: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Additional information may also be found at Engine; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Specifications > Page 11281
Oil Pressure Sender: Service and Repair
Removal and Installation
1. Discard the battery ground cable.
2. Disconnect the oil pressure sensor electrical connector and remove the sensor.
3. Note: Coat the threads of the oil pressure sensor with Pipe Sealant with Teflon D8AZ-19554-A or
Wsk-M2G350-A2.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside
Temperature Display Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside
Temperature Display Sensor > Component Information > Locations > Page 11286
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Overdrive Indicator Lamp > Component
Information > Locations > Page 11290
Overdrive Indicator Lamp: Description and Operation
Overdrive (O/D) Off
The O/D OFF indicator illuminates when the transmission is locked out of O/D. This dual function
indicator will also flash off and on if a transmission
malfunction is detected.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Assist Warning Indicator >
Component Information > Service and Repair
Parking Assist Warning Indicator: Service and Repair
REMOVAL
1. Remove the LH quarter trim panel.
2. Remove the parking aid speaker.
1 Disconnect the electrical connector.
2 Remove the pin-type retainers.
3 Remove the parking aid speaker.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions
Audible Warning Device Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11300
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11301
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11302
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11303
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11304
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11305
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11306
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11307
Audible Warning Device Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11308
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11309
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11310
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11311
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11312
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Diagram Information and Instructions >
Page 11313
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Page 11314
Audible Warning Device Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Page 11315
Audible Warning Device Control Module: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Audible Warning Device Control Module > Component Information > Diagrams > Page 11316
Audible Warning Device Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Gauge Module > Component Information > Description and Operation
Fuel Gauge Module: Description and Operation
NOTE:
- The fuel gauge and instrument cluster gauge amplifier must be replaced as a set. The fuel gauge
and instrument cluster gauge amplifier are calibrated together.
- If the ignition key is left in the ON position during fueling, a slow to respond fuel gauge indication
may result. The ignition key must be placed in the OFF position during or after refueling for
accurate fuel gauge indication.
The instrument cluster gauge amplifier electrically averages the fuel sender readings so the gauge
displays the actual fuel level and not the fluctuations due to fuel sloshing. The amplifier also
supplies the signal to illuminate the CHECK GAGE indicator to indicate low fuel, high engine
coolant temperature, or low engine oil pressure. The gauge amplifier is a small printed circuit board
located in a pocket on the back of the instrument cluster. The electrical connections are made with
a spring-type connector. There are no provisions for calibration or adjustment. The fuel gauge and
the instrument cluster gauge amplifier must be replaced as a unit.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Gauge Module > Component Information > Description and Operation > Page 11320
Fuel Gauge Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Fuel Gauge Module > Component Information > Description and Operation > Page 11321
Fuel Gauge Module: Service and Repair
Service and Repair
The fuel gauge and instrument cluster gauge amplifier (Slosh Module) are calibrated together and
must be replaced as a set.
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Locations > Page 11325
Instrument Panel Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Locations > Page 11326
Instrument Panel Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Instrument Panel Control Module > Component Information > Locations > Page 11327
Instrument Panel Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Panel Illumination Control Module > Component Information > Locations
Panel Illumination Control Module: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Panel Illumination Control Module > Component Information > Locations > Page 11331
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Panel Illumination Control Module > Component Information > Locations > Page 11332
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Panel Illumination Control Module > Component Information > Locations > Page 11333
Panel Illumination Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Panel Illumination Control Module > Component Information > Locations > Page 11334
Panel Illumination Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Panel Illumination Control Module > Component Information > Locations > Page 11335
Panel Illumination Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Information > Locations > Page 11339
Seat Belt Reminder Lamp: Description and Operation
The safety belt warning indicator is powered through the GEM/CTM module. When the ignition key
is turned on, the indicator illuminates for four to eight seconds even if the safety belt is buckled.
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component
Information > Locations > Page 11340
Seat Belt Reminder Lamp: Testing and Inspection
Testing and Inspection For further information regarding the diagnosis of this component and the
system that it is a part of, please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Service and Repair
Dimmer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Dimmer Switch > Component Information > Service and Repair > Page 11345
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Door Switch > Component Information > Locations > Page 11349
Door Switch: Service and Repair
REMOVAL
1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door
Latch.
3. Remove the door opening warning lamp switch.
1 Lift the locking tab.
2 Rotate the door opening warning lamp switch counterclockwise.
3 Remove the door opening warning lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Testing and Inspection
Fuel Gauge Sender: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Fuel Gauge Sender > Component Information > Testing and Inspection > Page 11353
Fuel Gauge Sender: Service and Repair
Service and Repair
For further information regarding this component please refer to Instrument Panel, Gauges and
Warning Indicators; Service and Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Key Reminder Switch > Component Information > Service and Repair
Key Reminder Switch: Service and Repair
For further information regarding the service of this component and the system that it is part of,
please refer to Instrument Panel, Gauges and Warning indicators; Service and Repair; Warning
Devices.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Outside Temperature Display Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel >
Outside Temperature Display Sensor > Component Information > Locations > Page 11360
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information >
Locations > Page 11364
Shift Indicator: Adjustments
1. Remove the upper instrument panel steering column cover. 2. Place the gearshift lever in the (D)
position.
- Rotate the gearshift lever clockwise until it bottoms out (first gear), then rotate two detents
counterclockwise (D) position).
3. Hang a 3.6 kg (8 lb.) weight on the gearshift lever.
4. Center the pointer in the middle of the (D) position.
- Rotate the thumbwheel located on the bottom of the steering column to adjust the pointer.
5. Remove the 3.6 kg (8 lb.) weight. 6. Carefully move the gearshift lever from detent to detent and
compare with the transmission settings.
- Readjust if necessary.
7. Install the upper instrument panel steering column cover.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Locations > Page 11368
Speedometer Head: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Locations > Page 11372
Tachometer: Description and Operation
The tachometer is a 6000 rpm tachometer. It has four terminals: one labeled B (12 to 1 4.5V), one
labeled S (EDIS tach signal in), and two labeled G (cylinder selection grounds). The bottom ground
(G) terminal is grounded. The top ground (G) terminal is grounded through a 4.32 kohm resistor in
a 6-cylinder engine vehicle and is connected directly to ground for an 8-cylinder engine vehicle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Locations > Page 11373
Tachometer: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Locations > Page 11377
Temperature Gauge: Testing and Inspection
Magnetic Gauge Testing
The Instrument Gauge System Tester is used to diagnose concerns with the instrument cluster
magnetic gauges.
To test the magnetic gauges:
^ Disconnect the connector from the appropriate sender and connect the signal wire to the
Instrument Gauge System Tester.
^ Turn the vehicle ignition switch lock cylinder to the ON position.
1. Disconnect water temperature indicator sender unit C104. Connect one lead of Instrument
Gauge System Tester to water temperature indicator
sender unit C104, circuit 39 (RD/WH), and the other lead to ground.
2. Set Instrument Gauge System Tester to 300 ohms. Key ON. Wait one minute. The engine
coolant temperature gauge should indicate C (cold).
Key OFF.
3. Set Instrument Gauge System Tester to 45 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge pointer should be in the one
quarter range to mid range. Key OFF.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Locations > Page 11378
4. Set Instrument Gauge System Tester to 18 ohms. Key ON. Wait one minute. The engine coolant
temperature gauge should indicate H (hot). Key
OFF.
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Instrument Panel, Gauges and Warning Indicators; Testing and Inspection. See:
Testing and Inspection/Instrument Cluster/Pinpoint Tests
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component
Information > Specifications
Temperature Sensor (Gauge): Specifications
Engine coolant temperature (ECT) sensor 89 in.lb
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component
Information > Specifications > Page 11382
Temperature Sensor (Gauge): Description and Operation
When the engine temperature is low, the resistance of the water temperature indicator sender unit
is high, thus restricting the flow of current through the gauge and moving the pointer only a short
distance. As the temperature of the coolant increases, the resistance decreases, allowing more
current to flow through the gauge and results in a corresponding movement of the pointer.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator,
Engine Cooling > Component Information > Description and Operation
Temperature Warning Lamp/Indicator: Description and Operation
This warning message is displayed when the engine coolant is overheating.
The message center indicator senses the voltage level on Circuit 39 (RD/WH) (to the message
center indicator).
If that voltage is greater than approximately 2.7 volts, at a battery voltage of 13.5 volts there will be
no warning. If it is less than approximately 2.7 volts , at a battery voltage of 13.5 volts then the
warning will be displayed.
The message center indicator filters this input; therefore, there will be a few seconds delay before
the warning is displayed or removed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Mode Indicator - A/T >
Component Information > Description and Operation
Transmission Mode Indicator - A/T: Description and Operation
TRANSMISSION CONTROL INDICATOR LAMP
The Transmission Control Indicator Lamp (TCIL) is an output signal from the PCM that controls the
lamp on/off function depending on the engagement or disengagement of overdrive. Refer to
Transmission Control Switch, PCM Inputs.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information
> Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations > Page 11396
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Specifications
Backup Lamp Switch: Specifications
Backup Lamp Switch 25-35 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Specifications > Page 11401
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Specifications > Page 11402
Backup Lamp Switch: Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information >
Specifications > Page 11403
Backup Lamp Switch: Service and Repair
REMOVAL
1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the
backup lamp switch electrical connector.
3. Remove the backup lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins >
Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling
Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins >
Customer Interest for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page 11412
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling
Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift Interlock Disabling > Page
11418
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Brake Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11421
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11422
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11423
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11424
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11425
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11426
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11427
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11428
Brake Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11429
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11430
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11431
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11432
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11433
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11434
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11435
Brake Lamp: Electrical Diagrams
For further information regarding this component please refer to :
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Brake Lamp: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the stoplamps. 2. Visually inspect for obvious signs of
mechanical and electrical damage.
VISUAL INSPECTION CHART
3. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See:
Symptom Related Diagnostic Procedures
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11438
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11439
Brake Lamp: Pinpoint Tests
J1 - J2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11440
J3 - J4
Test K: One or More Stoplamps Are Inoperative
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11441
K1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11442
K2 - K3
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11443
K4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Testing and Inspection > Page
11444
73 Digital Multimeter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component
Information > Locations
Exterior Lighting System Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component
Information > Locations > Page 11448
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component
Information > Locations > Page 11449
Brake Pedal Position Switch: Description and Operation
BRAKE PEDAL POSITION SWITCH
Typical Brake Pedal Position Switch
The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the
transmission torque converter clutch and on some applications as an input to the idle speed control
for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery
positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch
signal is broadcast over the SCP link via another module to be received by the PCM.
On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all
stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor
in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has
failed.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Brake Pedal Position Switch <--> [Brake Light Switch] > Component
Information > Locations > Page 11450
Brake Pedal Position Switch: Service and Repair
REMOVAL
1. Disconnect the brake pedal position (BPP) switch connector.
2. Remove the BPP switch
1 Remove the self-locking pin.
2 Remove the spacer.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Cargo Lamp > Component Information > Service and Repair
Cargo Lamp: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the lamp assembly.
1 Use a thin bladed tool to carefully pry the lamp assembly to the left.
2 Press the locking tab inward.
3 Lower the lamp assembly.
4 Disconnect electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical
Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift
Interlock Disabling
Center Mounted Brake Lamp: Customer Interest A/T - Inadvertent Shift Interlock Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical
Service Bulletins > Customer Interest for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T - Inadvertent Shift
Interlock Disabling > Page 11462
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling
Center Mounted Brake Lamp: All Technical Service Bulletins A/T - Inadvertent Shift Interlock
Disabling
Article No. 02-17-6
09/02/02
LAMP - BRAKE - INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK
FORD: 1992-1993 FESTIVA 1992-1994 TEMPO 1992-1997 THUNDERBIRD 1992-2003 CROWN
VICTORIA, ESCORT, MUSTANG, TAURUS 1993-1997 PROBE 1994-1997 ASPIRE 1995-2000
CONTOUR 2002-2003 THUNDERBIRD 1992-1997 AEROSTAR 1992-2003 E SERIES 1993-1997
F SUPER DUTY 1994-1996 BRONCO 1994-1997 F-250, F-350 1994-2003 F-150 1995-2003
EXPLORER, RANGER, WINDSTAR 1997-2003 EXPEDITION 1998-1999 F-250 LD 1999-2003
SUPER DUTY F SERIES 2000-2003 EXCURSION, EXPLORER SPORT 2001-2003 ESCAPE,
EXPLORER SPORT TRAC
LINCOLN: 1992-2003 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2003 LS
1998-2003 NAVIGATOR
MERCURY: 1992-1994 TOPAZ 1992-1997 COUGAR 1992-1999 TRACER 1992-2003 SABLE
1993-2003 GRAND MARQUIS 1994 CAPRI 1995-2000 MYSTIQUE 1999-2003 COUGAR
1993-2002 VILLAGER 1997-2003 MOUNTAINEER
Article 01-18-1 is being republished in its entirety to update the model year coverage and vehicle
line applications.
ISSUE
Corporate, municipal, or police fleets may have had their Ford Motor Company vehicle modified to
flash the brake lamps whenever the "police lights" or other aftermarket lights are turned on. These
added "police lights" have the potential to disable the brake shift interlock system. The brake shift
interlock feature prevents the vehicle from being shifted from park unless the brake pedal is
depressed. Disabling of the brake shift interlock feature may enable the operator to inadvertently
apply the accelerator instead of the brake pedal when shifting from Park to Drive or Reverse gears.
ACTION
As appropriate, dealers should advise owners (including corporate, municipal, and police agencies)
that any vehicle that has been modified with a connection to the brake circuit, or that electrically
interfaces with the brake lamps in that manner, should be disconnected IMMEDIATELY and the
emergency lighting system should be modified in a manner that does not interfere with normal
service operation or the brake shift interlock. In addition, if the high-mount stoplamp flashes when
the "police lights" are on, the modification does not conform with the Federal Motor Vehicle Safety
Standards
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Center Mounted Brake Lamp: > 02-17-6 > Sep > 02 > A/T Inadvertent Shift Interlock Disabling > Page 11468
(FMVSS) 108 which requires that the high-mount stoplamp only illuminate when applying the
brakes.
Installation of warning lights should only be performed with a completely separate electrical system,
without connection to any existing vehicle wiring. Connection of aftermarket electrical equipment
into the brake lamp circuit or any other circuit which is connected to the Powertrain Control Module
(PCM), anti-lock brake computer, air bag system, or any other vehicle system, will cause vehicle
malfunction.
OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 01-18-1 WARRANTY STATUS:
INFORMATION ONLY OASIS CODES: 203000, 203200, 205000, 301000, 503300
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical
Service Bulletins > Page 11469
Center Mounted Brake Lamp: Specifications
High Mounted Stoplamp Nuts 2.7-3.7 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical
Service Bulletins > Page 11470
Exterior Lighting System Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Technical
Service Bulletins > Page 11471
Center Mounted Brake Lamp: Service and Repair
REMOVAL
1. Remove the liftgate glass. Refer to Windows.
2. Remove the plugs.
3. Remove the nuts.
4. Remove the high-mounted stoplamp.
1 Disconnect the electrical connector.
2 Remove the high-mounted stoplamp.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Service
and Repair
Interior Light Switch: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Remove the interior lamp switch.
1 Disconnect the interior lamp switch electrical connector.
2 Remove the interior lamp switch. ^
Push inward; rotate counterclockwise.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Specifications
Daytime Running Lamp Control Unit: Specifications
Daytime Running Lamps Control Module Bolts 3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Specifications > Page 11480
Daytime Running Lamp Control Unit: Locations
Left front corner of engine.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Specifications > Page 11481
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit >
Component Information > Specifications > Page 11482
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the daytime running lamps (DRL) control module.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the DRL control module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair
Dimmer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Service and Repair > Page
11486
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations
Battery Discharge Protection Relay: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 11490
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 11491
Battery Discharge Protection Relay: Description and Operation
The following components are under the control of the battery saver relay:
^ Delayed accessory relay.
^ Overhead interior lamp with map lamps.
^ Overhead interior lamp switch.
^ Interior lamp relay coil.
The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake
mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode.
The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have
passed since the last active input. At that time, the relay will be deactivated and power to the above
circuits will terminate.
Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower
power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will
monitor only select inputs.
Logical characteristics of the GEM battery saver mode are as follows:
Feature Input: ^
Sleep/awake mode status.
Feature Output: ^
Battery saver relay control (open circuit in sleep mode, grounded when awake).
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 11492
Battery Discharge Protection Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Battery Discharge Protection Relay, Lighting > Component Information >
Locations > Page 11493
Battery Discharge Protection Relay: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Rear
Domelamp Assembly
Dome Lamp: Service and Repair Rear Domelamp Assembly
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the lamp assembly.
1 Use a thin bladed tool to carefully pry the lamp assembly to the left.
2 Press the locking tab inward.
3 Lower the lamp assembly.
4 Disconnect electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Rear
Domelamp Assembly > Page 11498
Dome Lamp: Service and Repair Front Domelamp Assembly
REMOVAL
1. Disconnect the battery ground cable.
2. Use a thin bladed tool to carefully pry the dome lamp lens out.
^ Replace the bulb if necessary.
3. Remove the screws and lower the lamp assembly.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 11502
Door Switch: Service and Repair
REMOVAL
1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door
Latch.
3. Remove the door opening warning lamp switch.
1 Lift the locking tab.
2 Rotate the door opening warning lamp switch counterclockwise.
3 Remove the door opening warning lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page
11506
Exterior Lighting Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page
11507
Exterior Lighting Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Exterior Lighting Module > Component Information > Locations > Page
11508
Exterior Lighting Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 11513
Fog/Driving Lamp Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information >
Specifications
Fog/Driving Lamp Switch: Specifications
Fog Lamp Switch Mounting Bezel Screws 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information >
Specifications > Page 11517
Exterior Lighting System Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information >
Specifications > Page 11518
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information >
Specifications > Page 11519
Fog/Driving Lamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel.
3 Disconnect the electrical connectors.
3. Remove the fog lamp switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the fog lamp switch.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information >
Specifications > Page 11520
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Locations > Page 11525
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams
Hazard Warning Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 11529
Hazard Warning Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 11530
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 11531
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Diagrams > Page 11532
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service
Precautions
Headlamp Bulb: Service Precautions
WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY
SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED.
HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING
THE GLASS ENVELOPE.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service
Precautions > Page 11537
Headlamp Bulb: Service and Repair
REMOVAL
WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY
SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED.
HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING
THE GLASS ENVELOPE.
NOTE: The headlamp bulb should not be removed from the headlamp until just before a
replacement bulb is installed. Removing the bulb for an extended period of time may affect
headlamp bulb performance. Contaminants may enter the headlamp where they can settle on the
lens and reflector. Never turn the headlamps on with the bulb removed.
1. Remove the headlamp assembly.
2. Rotate the headlamp bulb retainer counterclockwise and remove.
3. Remove the headlamp bulb.
INSTALLATION
1. To install, reverse the removal procedure.
WARNING: THE HALOGEN BULB CONTAINS GAS UNDER PRESSURE. THE BULB MAY
SHATTER IF THE GLASS ENVELOPE IS SCRATCHED OR IF THE BULB IS DROPPED.
HANDLE THE BULB CAREFULLY. GRASP THE BULB ONLY BY ITS BASE. AVOID TOUCHING
THE GLASS ENVELOPE.
NOTE: ^
Never turn the head lamps on with the bulb removed.
^ When the battery is disconnected and reconnected, some abnormal drive symptoms may occur
while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 mi) or
more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Relay > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Relay > Component Information >
Locations > Page 11541
Headlamp Dimmer Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams
Headlamp Dimmer Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 11545
Headlamp Dimmer Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 11546
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 11547
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Diagrams > Page 11548
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations >
Page 11552
Headlamp Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If
resistance is 5 ohms or less between terminal 2 and any
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations >
Page 11553
other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two
jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73
Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not
indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal
2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage
is not indicated, replace the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications
Headlamp Switch: Specifications
Head Lamp Switch Screws 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Specifications >
Page 11557
Exterior Lighting System Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11560
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11561
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11562
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11563
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11564
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11565
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11566
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11567
Headlamp Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11568
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11569
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11570
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11571
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11572
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11573
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Diagram Information and Instructions > Page 11574
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11575
Headlamp Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11576
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11577
Headlamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening
cover reinforcement; refer to Dashboard.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the instrument panel finish panel.
4. Remove the instrument cluster finish panel.
1 Remove the screws.
2 Remove the cluster instrument panel finish panel.
5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 11578
6. Remove the headlamp switch.
1 Remove the screws.
2 Remove the headlamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Horn Relay: Locations
Part (1 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11583
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11584
Horn Relay: Testing and Inspection
Terminals
Component Testing Procedure
Schematic
Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay
terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the
volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the
relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the
jumper wire to a known good
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 11585
ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation
Horn Switch: Description and Operation
The horn blow switches are underneath the driver side air bag module in the steering wheel. The
switches are powered through the air bag sliding contact and ground through the steering column.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Description and Operation
> Page 11589
Horn Switch: Service and Repair
REMOVAL
1. Remove the driver side air bag; refer to Air Bag Systems.
2. Remove the switches.
1 Disconnect the horn wire (BK) from the switches.
2 Remove the attaching bolts from the switches and remove the switches.
INSTALLATION
1. To install, reverse the removal procedure.
^ Prove out the air bag system; refer to Air Bag Systems.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11595
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11596
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11597
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11598
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11599
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11600
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11601
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11602
Interior Lighting Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11603
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11604
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11605
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11606
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11607
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 11608
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page
11609
Interior Lighting Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page
11610
Interior Lighting Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Module > Component Information > Diagrams > Page
11611
Interior Lighting Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Interior Lighting Relay > Component Information > Locations > Page 11615
Interior Lighting Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions
License Plate Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11620
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11621
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11622
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11623
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11624
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11625
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11626
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11627
License Plate Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11628
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11629
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11630
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11631
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11632
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11633
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Diagram
Information and Instructions > Page 11634
License Plate Lamp: Electrical Diagrams
For further information regarding this component please refer to :
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 11635
License Plate Lamp: Testing and Inspection
For Further information regarding the diagnosis of this component and the system that it is a part
of, please refer to Lighting and Horns; Parking Lamp; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Map Light > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Marker Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11643
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11644
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11645
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11646
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11647
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11648
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11649
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11650
Marker Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11651
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11652
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11653
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11654
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11655
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11656
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11657
Marker Lamp: Electrical Diagrams
For further information regarding this component please refer to :
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
Parking Lamp Relay: Locations
Relay Module
Parking Lamp Relay is located in the relay module. Relay module is located behind center of I/P.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information > Locations
> Page 11662
Parking Lamp Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations
Battery Discharge Protection Relay: Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 11667
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 11668
Battery Discharge Protection Relay: Description and Operation
The following components are under the control of the battery saver relay:
^ Delayed accessory relay.
^ Overhead interior lamp with map lamps.
^ Overhead interior lamp switch.
^ Interior lamp relay coil.
The battery saver relay becomes active (relay coil is energized) when the GEM is in the awake
mode, and is deactivated (relay coil is de-energized) when the GEM is in the sleep mode.
The battery saver will remain active until the ignition state is not ACC or RUN and 45 minutes have
passed since the last active input. At that time, the relay will be deactivated and power to the above
circuits will terminate.
Five minutes after the battery saver relay has become deactivated, the GEM will go into a lower
power state known as sleep mode. In the sleep mode, the GEM will deactivate all outputs and will
monitor only select inputs.
Logical characteristics of the GEM battery saver mode are as follows:
Feature Input: ^
Sleep/awake mode status.
Feature Output: ^
Battery saver relay control (open circuit in sleep mode, grounded when awake).
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 11669
Battery Discharge Protection Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Battery Discharge Protection
Relay, Lighting > Component Information > Locations > Page 11670
Battery Discharge Protection Relay: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications
Daytime Running Lamp Control Unit: Specifications
Daytime Running Lamps Control Module Bolts 3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 11674
Daytime Running Lamp Control Unit: Locations
Left front corner of engine.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 11675
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp
Control Unit > Component Information > Specifications > Page 11676
Daytime Running Lamp Control Unit: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. For additional information, refer to Battery.
2. Remove the daytime running lamps (DRL) control module.
1 Disconnect the electrical connector.
2 Remove the bolts.
3 Remove the DRL control module.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Locations > Page 11680
Exterior Lighting Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Locations > Page 11681
Exterior Lighting Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Exterior Lighting Module >
Component Information > Locations > Page 11682
Exterior Lighting Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 11686
Fog/Driving Lamp Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay >
Component Information > Locations > Page 11690
Headlamp Dimmer Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component
Information > Locations > Page 11694
Headlamp Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If
resistance is 5 ohms or less between terminal 2 and any
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component
Information > Locations > Page 11695
other terminal, replace the relay. If resistance is greater than 5 ohms, continue the test. Use two
jumper wires to connect relay terminals 1 and 3 directly to the positive battery terminal. Set 73
Digital Multimeter in volts position and check for voltage at terminal 4. If battery voltage is not
indicated, replace the relay. If battery voltage is indicated, connect the third jumper wire to terminal
2, and ground the jumper wire to chassis ground. Check for voltage at terminal 5. If battery voltage
is not indicated, replace the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Horn Relay: Locations
Part (1 Of 2)
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 11699
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 11700
Horn Relay: Testing and Inspection
Terminals
Component Testing Procedure
Schematic
Use 73 Digital Multimeter to check for continuity between terminal 2 and all other terminals. If
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue the test. Use two jumper wires to connect relay
terminal 1 and terminal 3 directly to the positive battery terminal. Set 73 Digital Multimeter in the
volts position and check for voltage at terminal 4. If battery voltage is not indicated, replace the
relay. If battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the
jumper wire to a known good
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 11701
ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions
Interior Lighting Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11707
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11708
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11709
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11710
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11711
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11712
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11713
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11714
Interior Lighting Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11715
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11716
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11717
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11718
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11719
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 11720
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Page 11721
Interior Lighting Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Page 11722
Interior Lighting Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Module >
Component Information > Diagrams > Page 11723
Interior Lighting Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Interior Lighting Relay >
Component Information > Locations > Page 11727
Interior Lighting Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Parking Lamp Relay: Locations
Relay Module
Parking Lamp Relay is located in the relay module. Relay module is located behind center of I/P.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations > Page 11731
Parking Lamp Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Turn Signal Relay >
Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor >
Component Information > Locations > Page 11739
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Specifications
Backup Lamp Switch: Specifications
Backup Lamp Switch 25-35 Nm
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Specifications > Page 11743
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Specifications > Page 11744
Backup Lamp Switch: Diagrams
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch >
Component Information > Specifications > Page 11745
Backup Lamp Switch: Service and Repair
REMOVAL
1. Raise and support the vehicle; refer to Maintenance/Service and Repair. 2. Disconnect the
backup lamp switch electrical connector.
3. Remove the backup lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch
<--> [Brake Light Switch] > Component Information > Locations
Exterior Lighting System Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch
<--> [Brake Light Switch] > Component Information > Locations > Page 11749
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch
<--> [Brake Light Switch] > Component Information > Locations > Page 11750
Brake Pedal Position Switch: Description and Operation
BRAKE PEDAL POSITION SWITCH
Typical Brake Pedal Position Switch
The Brake Pedal Position (BPP) switch (Figure 21) is used by the PCM to disengage the
transmission torque converter clutch and on some applications as an input to the idle speed control
for idle quality. On most applications the BPP switch is hard wired to the PCM and supplies battery
positive voltage (B+) when the vehicle brake pedal is applied. On other applications the BPP switch
signal is broadcast over the SCP link via another module to be received by the PCM.
On applications where the BPP switch is hard wired to the PCM and stoplamp circuit, if all
stoplamp bulbs are burned out (open), high voltage is present at the PCM due to a pull-up resistor
in the PCM. This provides fail-safe operation in the event the circuit to the stop amp bulbs has
failed.
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Pedal Position Switch
<--> [Brake Light Switch] > Component Information > Locations > Page 11751
Brake Pedal Position Switch: Service and Repair
REMOVAL
1. Disconnect the brake pedal position (BPP) switch connector.
2. Remove the BPP switch
1 Remove the self-locking pin.
2 Remove the spacer.
3 Remove the BPP switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Testing and Inspection
Combination Switch: Testing and Inspection
For further information regarding this component please refer to Turn Signal Switch; Testing and
Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Testing and Inspection > Page 11755
Combination Switch: Service and Repair
For further information regarding this component please refer to Turn Signal Switch; Service and
Repair.
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component
Information > Locations > Page 11759
Door Switch: Service and Repair
REMOVAL
1. Remove the door trim panel. 2. Remove the door latch. For additional information, refer to Door
Latch.
3. Remove the door opening warning lamp switch.
1 Lift the locking tab.
2 Rotate the door opening warning lamp switch counterclockwise.
3 Remove the door opening warning lamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch >
Component Information > Specifications
Fog/Driving Lamp Switch: Specifications
Fog Lamp Switch Mounting Bezel Screws 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch >
Component Information > Specifications > Page 11763
Exterior Lighting System Components
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch >
Component Information > Specifications > Page 11764
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch >
Component Information > Specifications > Page 11765
Fog/Driving Lamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the instrument panel finish panel.
1 Remove the screws.
2 Remove the center instrument panel finish panel.
3 Disconnect the electrical connectors.
3. Remove the fog lamp switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the fog lamp switch.
INSTALLATION
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch >
Component Information > Specifications > Page 11766
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams
Hazard Warning Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 11770
Hazard Warning Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 11771
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 11772
Schematic
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Diagrams > Page 11773
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams
Headlamp Dimmer Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 11777
Headlamp Dimmer Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 11778
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 11779
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch >
Component Information > Diagrams > Page 11780
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Specifications
Headlamp Switch: Specifications
Head Lamp Switch Screws 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Specifications > Page 11784
Exterior Lighting System Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions
Headlamp Switch: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11787
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11788
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11789
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11790
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11791
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11792
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11793
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11794
Headlamp Switch: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11795
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11796
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11797
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11798
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11799
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11800
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Diagram Information and Instructions > Page 11801
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11802
Headlamp Switch: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11803
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11804
Headlamp Switch: Service and Repair
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the instrument panel steering column opening
cover reinforcement; refer to Dashboard.
3. Remove the center instrument panel finish panel.
1 Remove the screws.
2 Remove the instrument panel finish panel.
4. Remove the instrument cluster finish panel.
1 Remove the screws.
2 Remove the cluster instrument panel finish panel.
5. Disconnect the headlamp switch electrical connectors and remove the headlamp switch knob.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 11805
6. Remove the headlamp switch.
1 Remove the screws.
2 Remove the headlamp switch.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Description and Operation
Horn Switch: Description and Operation
The horn blow switches are underneath the driver side air bag module in the steering wheel. The
switches are powered through the air bag sliding contact and ground through the steering column.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Description and Operation > Page 11809
Horn Switch: Service and Repair
REMOVAL
1. Remove the driver side air bag; refer to Air Bag Systems.
2. Remove the switches.
1 Disconnect the horn wire (BK) from the switches.
2 Remove the attaching bolts from the switches and remove the switches.
INSTALLATION
1. To install, reverse the removal procedure.
^ Prove out the air bag system; refer to Air Bag Systems.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Component Information > Service and Repair
Interior Light Switch: Service and Repair
REMOVAL
1. Remove the front door trim panel.
2. Remove the interior lamp switch.
1 Disconnect the interior lamp switch electrical connector.
2 Remove the interior lamp switch. ^
Push inward; rotate counterclockwise.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams
Turn Signal Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11816
Turn Signal Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11817
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11818
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11819
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11820
Turn Signal Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 11821
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch >
Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
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Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch >
Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 11826
OASIS CODES: 201000, 201200
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications
Tail Lamp: Specifications
Rear lamp Assembly Screws 1.6-2.2 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Specifications > Page 11830
Exterior Lighting System Components
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions
Tail Lamp: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11833
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11834
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11835
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11836
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11837
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11838
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11839
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11840
Tail Lamp: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11841
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11842
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11843
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11844
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11845
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11846
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Diagram Information
and Instructions > Page 11847
Tail Lamp: Electrical Diagrams
For further information regarding this component please refer to :
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11848
Tail Lamp: Testing and Inspection
For Further information regarding the diagnosis of this component and the system that it is a part
of, please refer to Lighting and Horns; Parking Lamp; Testing and Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11849
Tail Lamp: Service and Repair
REMOVAL
1. Raise the liftgate and remove the rear lamp screws.
2. Remove the rear lamp. Disconnect the electrical connectors.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview
Trailer Lamps: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the trailer tow lights. 2. Verify the exterior lighting
system of the vehicle is operating properly. If not, refer to the appropriate pinpoint test. 3. Visually
inspect for obvious signs of electrical damage.
VISUAL INSPECTION CHART
Electrical ^
Central Junction Box (CJB) Fuse 3 (7.5 A)
^ CJB Fuse 7 (7.5 A)
^ CJB Fuse 30 (15 A)
^ Loose or corroded connections
^ Damaged circuity
^ Damaged relays
^ Failed bulb(s)
4. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See:
Symptom Related Diagnostic Procedures
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11854
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11855
Trailer Lamps: Pinpoint Tests
Connector Circuit Reference
Refer to the Vehicle/Diagrams for schematic and connector information.
AA1 - AA2
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Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11856
AB1 - AB2
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Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11857
AC1
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Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11858
AD1
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Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11859
AE1 - AE2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Trailer Lamps > Component Information > Testing and Inspection > Initial
Inspection and Diagnostic Overview > Page 11860
73 Digital Multimeter
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing
and Inspection
Combination Switch: Testing and Inspection
For further information regarding this component please refer to Turn Signal Switch; Testing and
Inspection.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Testing
and Inspection > Page 11865
Combination Switch: Service and Repair
For further information regarding this component please refer to Turn Signal Switch; Service and
Repair.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview
Turn Signal Lamp: Initial Inspection and Diagnostic Overview
1. Verify the customer concern by operating the turn signal/hazard flasher lamps. 2. Visually
inspect for obvious signs of mechanical and electrical damage.
VISUAL INSPECTION CHART
3. If the fault is not visually evident, determine the symptom and proceed to Symptom Chart. See:
Symptom Related Diagnostic Procedures
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11873
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11874
Turn Signal Lamp: Pinpoint Tests
L1 - L2
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11875
L3 - L4
Test M: Hazard Flasher Lamps Are Never ON
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11876
M1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11877
M2 - M3
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11878
M4
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11879
N1
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11880
Turn Signal Lamp: Component Tests and General Diagnostics
Refer to Vehicle/Diagrams for schematic and connector information.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Testing and
Inspection > Initial Inspection and Diagnostic Overview > Page 11881
Special Service Tool(s)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Relay > Component Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams
Turn Signal Switch: Diagrams
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11888
Turn Signal Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11889
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11890
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11891
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11892
Turn Signal Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams >
Page 11893
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised
Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised
Article No. 01-21-6
10/29/01
ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE
MERCURY HOOD LAMP SWITCH
FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996
MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996
BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION
LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995
MARK VIII 2002 NAVIGATOR
MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996
COUGAR 1997-2001 MOUNTAINEER
ISSUE
This article is to provide information on replacement hood lamp switches. The 27 degree Mercury
style hood switches will no longer be available. Replacement 27 degree Mechanical switches will
be available as a service replacement.
ACTION
For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with
new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year
Workshop Manual as needed.
Parts Block
OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Engine Compartment Lamp <--> [Underhood Lamp] > Underhood Lamp
Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 11899
OASIS CODES: 201000, 201200
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Service and Repair
Vanity Lamp: Service and Repair
REMOVAL
1. Disconnect the battery ground cable.
2. Remove the sun visor.
^ Position the sun visor as necessary.
^ Remove the sun visor screws.
3. Lower the sun visor and disconnect the electrical connector.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11908
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11909
Heated Glass Element Relay: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Relay > Component
Information > Locations > Page 11910
Schematic
Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals.
If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the
volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the
relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the
jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not
indicated, replace the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component
Information > Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair
Rear Defogger: Technical Service Bulletins A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair
TSB 04-24-5
12/13/04
REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR TERMINAL TAB REPAIR
FORD: 1999-2000 Contour 1999-2002 Escort 1999-2003 Escort ZX2 1999-2005 Crown Victoria,
Mustang, Taurus 2000-2005 Focus 2005 Five Hundred, Freestyle 1999-2003 Windstar 1999-2005
Expedition, Explorer 2000-2005 Excursion 2001-2003 Explorer Sport 2001-2005 Escape
2004-2005 F-150, Freestar 2005 Escape Hybrid
LINCOLN: 1999-2002 Continental 1999-2005 Town Car 2000-2005 LS 1999-2005 Navigator
2002-2003 Blackwood 2003-2005 Aviator
MERCURY: 1999 Tracer 1999-2000 Mystique 1999-2005 and Marquis, Sable 2005 Montego
1999-2002 Villager 1999-2005 Mountaineer 2004-2005 Monterey 2005 Mariner
This article supersedes TSB 04-18-9 to update vehicle applications and service procedure.
ISSUE Some vehicles may exhibit inoperative electric rear window defroster (heated back lite) grid
lines, integral antenna concerns causing radio reception issues or terminal tabs pulled from the
rear window glass.
ACTION Follow the diagnostic and repair procedures included in this article to inspect and service
rear defroster grid lines, integral antenna concerns or broken terminal tabs.
SERVICE PROCEDURE
Warrantable/Non Warrantable repairs
Warrantable grid line repairs typically can be identified by one inoperative grid line with a small
discoloration at the area of concern, approximately the size of a pinhead. Grid line(s) that are
scratched or have the silver material removed are not warrantable and should be addressed with
the customer. Replacement of backglass for grid line or bus bar tarnishing is not a warrantable
repair. Tarnishing of the silver lines or bus bars is a normal condition. Please refer to the Heated
Back Lite Damageability Job Aid for additional information and examples of defects and damage.
NOTE
THE GRID LINE MATERIAL IS NOT EMBEDDED INTO THE GLASS BUT IS BAKED TO THE
GLASS SURFACE AND CONSEQUENTLY CAN BE SCRAPED OFF. INOPERATIVE LINES MAY
APPEAR TO THE EYE TO BE UNDAMAGED DUE TO RESIDUE REMAINING ON
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11918
THE GLASS AND WILL REQUIRE DIAGNOSIS WITH A VOLTMETER OR 12V TEST LAMP AS
EXPLAINED IN THIS ARTICLE.
Examples Of Non-Warrantable Grid Line Damage
^ Ice scraper damage to grid lines
^ Animal scratches on grid lines
^ Window tint film/removal of the film which damages grid lines
^ Stickers placed over grids which upon removal, removes the grid line material
^ License plate (steel type placed against the inside of back glass) which rubs on the grid line
causing damage
^ Temporary license plate (paper stuck on to the inside of the back glass) which upon removal
removes grid line material
^ Cargo or lumber rubbing against the glass which removes grid line material
^ Cellular phone antenna installation/removal which damages grid line material
NOTE
AN UNDAMAGED GRIDLINE WILL HAVE SMALL RIDGES THAT PROJECT ABOVE THE
SURFACE OF THE GLASS AND CAN EASILY BE FELT WHEN RUNNING A FINGERNAIL
ACROSS THEM.
GRIDLINES THAT HAVE BEEN "RAZOR BLADED" WILL FEEL SMOOTH WHEN A FINGERNAIL
IS DRAGGED ACROSS THE AFFECTED AREA. THERE MAY BE SOME RESIDUE LEFT ON
THE GLASS THAT APPEARS TO BE GRID MATERIAL BUT A CHECK WITH A VOLTMETER OR
12V TEST LAMP, AS EXPLAINED IN THIS ARTICLE, WILL CONFIRM AN OPEN CIRCUIT. GRID
LINE INOPERATIVE - DIAGNOSTICS
1. Reference Workshop Manual Section 501-11 and the Wiring Diagram Section 56 to verify power
and ground to the back-glass.
2. Connect a test lamp or DVOM to a good body ground.
3. Turn the ignition key to the run position and depress and release the rear defroster button to turn
the system on. THE GRID IS ENERGIZED FOR APPROXIMATELY 10 MINUTES EACH TIME
THE DEFROSTER BUTTON IS PRESSED.
4. Starting from the top grid line at the center of the back-glass, touch the test lamp or DVOM +
lead to each grid line. (Use caution not to damage grid lines). The DVOM should read
approximately 1/2 of the battery voltage on each line at the center of the back-glass. If using a test
light, the bulb should be approximately the same brightness on each line from top to bottom. If the
DVOM or light indicates a high voltage or no voltage on any grid line, move along the concern grid
line with the + test lead or test lamp until the voltage changes suddenly. This is the area of
concern, use chalk to mark the area of concern and mark the outside of the glass at that same
area.
5. Repair per the Grid Line Repair Procedure.
GRID LINE REPAIR PROCEDURE
NOTE
LONG GAPS ARE ALMOST ALWAYS DUE TO DAMAGE AND ARE NOT WARRANTABLE,
HOWEVER THEY CAN BE REPAIRED. THE LONGER THE GAP THE MORE IMPORTANT IT IS
TO APPLY A MINIMUM SIX (6) COATS OF CONDUCTIVE REPAIR MATERIAL WITH THE FIVE
(5) MINUTE DRY TIME BETWEEN EACH COAT. APPLYING LESS COATS OR NOT ALLOWING
DRY TIME BETWEEN COATS WILL PRODUCE REPAIRED RESISTANCE THAT IS GREATER
THAN OEM RESISTANCE, RESULTING IN POOR DEFROST PERFORMANCE AND
EXCESSIVE LOCALIZED HEATING. REPAIRED LONG GAPS ARE GENERALLY NOT
VISUALLY PLEASING UNLESS EXTREME CARE IS TAKEN WHEN TAPING AFFECTED GRID
LINE AREAS.
NOTE
IF THE BROWN COLOR UNDER THE GRID LINE IS DAMAGED OR MISSING (THIS IS VERY
RARE), IT WILL BE NECESSARY TO APPLY BROWN ACRYLIC LACQUER TOUCH-UP PAINT
FOR COLOR MATCH. THIS PAINT MUST MEET SPECIFICATION ESR-M2P100-C AND
SHOULD BE APPLIED TO THE GLASS PRIOR TO APPLYING THE REAR WINDOW
DEFROSTER REPAIR COMPOUND.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11919
Service inoperative grid lines on rear window glass using Motorcraft Defroster Repair PM-11 or
equivalent meeting Ford specification ESB-M4J58-A as follows:
Surface Preparation
1. Bring vehicle inside and warm it to 60° F (16° C) or above.
2. Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of
the rear window glass as this may cause damage to the grid lines. Clean the entire grid line service
area with Ultra Clear Spray Glass Cleaner ZC-23 or equivalent meeting Ford specification
ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the
repair area be clean and dry.
NOTE
THE REPAIR AREA HOWEVER SHOULD BE CLEANED WITH STEEL WOOL OR AN ABRASIVE
PAD SUCH AS SCOTCHBRITE TO REMOVE GRIME.
Mixing
The bottle of Rear Window Defroster Repair compound and touch-up paint (if needed) must be at
room temperature. Shake the bottle for at least one (1) minute for thorough mixing. Shake
frequently during use.
Application
1. Mark location of open grid on the outside of the back window glass (performed in diagnostics).
Place protective covering over the package tray as necessary.
2. Using "fine line tape", mask off the area directly above and below open grid line (Figure 1). It is
best to extend the tape 26 mm (1") beyond the concern area in both directions. The open should
be at the center of the mask and tape gap must be no wider than the existing grid line. Other types
of tape may be used but end results of the repair may not appear as visually acceptable due to
ease of application and tape edge finish.
3. If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound
to the open grid line. Apply the correct coating in several smooth continuous strokes (allowing five
(5) minutes drying time between coats) across the open grid line area using the brush applicator in
the cap. Extend the service coating at least 6 mm (.25") on both sides of the open grid line area.
Apply a minimum of six (6) coats of the grid repair compound.
4. If both brown and silver layers of the grid are broken or missing, apply a coating of brown
lacquer touch-up paint across the open line area first. Take care to paint only the area missing the
color. Two (2) coats may be necessary to obtain the proper color. Allow the touch-up paint to dry at
least five (5) minutes between coats. Apply six (6) coats of grid repair compound.
NOTE
THE INTERIOR SIDE OF THE GRID LINES ARE NOT PAINTED, BUT DUE TO THE SILVER
TARNISHING WILL TEND TO CHANGE THE GRID TO A GOLD OR BROWN COLOR. THE
REPAIRED AREA WILL BE BRIGHT SILVER AND WILL ALSO TARNISH OVER
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11920
TIME TO MATCH THE REST OF THE GRID.
5. After five (5) minutes of dry time of the final coat of grid repair compound, remove the tape, step
outside and inspect the repaired area. If the repair compound is visible above or below the grid, the
excess can be removed. This may be done by placing a single-edge razor blade on the back
window glass parallel to grid and scrape gently toward grid. A wider/thicker line will perform better
but may not be cosmetically appealing.
CAUTION
BE CAREFUL NOT TO DAMAGE GRID LINE WITH RAZOR BLADE. VERIFY ALL OF THE GRID
LINES FUNCTION PROPERLY WHEN FINISHED.
Curing
The service coating will air-dry in approximately one (1) minute and the system can be energized
after five minutes. Maximum hardness and adhesion occur after approximately 24 hours.
SOLDER METHOD OF LEAD TERMINAL
NOTE
THE REAR WINDOW MUST BE AT A MINIMUM OF 60° F (16° C) BEFORE A REPAIR IS MADE.
PLACE PROTECTIVE COVERING OVER THE PACKAGE TRAY AS NECESSARY.
The new terminal will cover the original terminal location, but must be placed so that the new
terminal conductive areas will be placed on a good conductive base. This area should be cleaned
with steel wool or an abrasive pad to remove grime from the buss-bar. The area should then be
cleaned with Ultra Clear Spray Glass Cleaner, ZC-23, or equivalent meeting Ford specification
ESR-M14P5-A to remove all dirt, wax, grease, oil or other foreign matter. It is important that the
repair area be clean and dry and appear metallic. Depending on the buss-bar condition, rigorous
polishing with steel wool may be required. Please note that the entire buss-bar may be cleaned to
improve appearance.
CAUTION
DO NOT USE ANY TYPE OF FLAME TORCH OR FLAME HEATED SOLDERING GUN FOR THIS
PROCEDURE. TESTING INDICATED INADEQUATE HEAT GENERATION AT THE TIP AND THE
EXHAUST HEAT CAN CAUSE DAMAGE TO PLASTIC TRIM PARTS IN THE AREA. USE ONLY
AN ELECTRIC SOLDERING GUN WITH 100 WATTS OR MORE OF POWER.
BEFORE USING THE SOLDERING GUN, BE SURE TO MELT A SMALL AMOUNT OF ROSIN
CORE SOLDER TO THE TIP. THE SOLDER WILL ASSIST IN ACHIEVING BETTER HEAT
TRANSFER FROM THE SOLDERING GUN TIP TO THE NEW TERMINAL.
The new terminal has pre-applied solder, flux and temperature sensitive paint. The paint provides a
visual indication when the terminal has reached the proper temperature to melt the solder on the
terminal. When the proper temperature is achieved the temperature paint will liquefy and change
color.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11921
Use terminal type A (Figure 2) for all tab locations except on the Focus vehicle line. For the Focus,
use type B (Figure 3).
NOTE
DEPENDING ON THE ORIGINAL TERMINAL LOCATION, AND WHETHER THE TERMINAL IS
COVERED BY PILLAR TRIM, WILL DETERMINE WHERE TO LOCATE THE NEW TERMINAL.
SOME GRID LINE BUSS-BARS MAY ONLY ALLOW THE PLACEMENT OF THE TERMINAL
ABOVE OR BELOW THE ORIGINAL TAB LOCATION DUE TO SPACE LIMITATIONS, BUT FOR
MOST VEHICLE APPLICATIONS THE REPLACEMENT TAB LOCATION WILL COVER THE
ORIGINAL TAB LOCATION BUT STILL ALLOW THE REPLACEMENT TAB TO ATTACH TO THE
BUSS-BAR ON GOOD CONDUCTIVE MATERIAL.
1. Place the replacement terminal over the original tab location making sure the conductive areas
of the terminal will be on a good conductive area. Do not place the terminal tab foot on the original
location which does not have conductive material (figure 4).
2. Hold the terminal in place with an item such as regular lead pencil at a 90 degree angle from the
terminal. (Terminal type B can be held in place with tape.) (Holding at other than a 90 degree angle
may allow the terminal to slip when the solder liquefies).
3. Place the soldering gun tip on the top of the terminal but not on the painted areas of the tab.
Energize the soldering gun and watch for the painted area of the terminal to liquefy and change
color. The paint should liquefy in approximately 25-45 seconds after heating. As soon as the paint
color completely changes on either side of the terminal, de-energize the soldering gun and
continue to hold the terminal in place with the soldering gun and pencil for an additional thirty (30)
seconds.
4. Remove the soldering gun and pencil from the terminal. The terminal should be allowed to cool
for another two (2) minutes before the wiring lead is attached to the terminal.
5. Attach the electrical lead connection to this terminal, turn on the rear defroster, and verify
operation.
Parts Block
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins >
A/C/Audio - Defroster/Antenna Grid Diagnosis/Repair > Page 11922
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042405A Repair Grid Lines (Includes 0.7 Hr.
Time To Diagnose And Recheck)
042405B Replace Terminal (Includes 0.4 Hr.
Time To Diagnose And Recheck)
042405C Repair Grid Lines And 0.8 Hr.
Replace Terminal (Includes Time To Diagnose And Recheck)
DEALER CODING
CONDITION
BASIC PART NO. CODE
7042006 28
Disclaimer
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11927
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11928
Heated Glass Element Relay: Testing and Inspection
Component Testing Procedure
Terminals
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Heated Glass Element Relay
> Component Information > Locations > Page 11929
Schematic
Use 73III Automotive Meter to check for the continuity between terminal 85 and all other terminals.
If resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 86 and 30 directly to the positive battery terminal. Use 73III Automotive Meter set in the
volts position to check for voltage at terminal 87A. If battery voltage is not indicated, replace the
relay. If battery voltage is indicated, connect a third jumper wire to terminal 85, and ground the
jumper wire to a known good ground. Check for voltage at terminal 87. If battery voltage is not
indicated, replace the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions
Power Window Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11935
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11936
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Control
Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11937
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11938
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11941
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11942
Power Window Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Power Window Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
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Power Window Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
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Power Window Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
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Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay >
Component Information > Locations
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Component Information > Locations > Page 11955
Power Window Relay: Description and Operation
LH Front Window Regulator Control Switch Inputs Table
The GEM controls manual down and OTD window movement with the OTD relay.
The relay is activated by applying ground directly to one side of the down window relay coil, and is
deactivated by removing the ground signal.
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Component Information > Locations > Page 11956
Power Window Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element
Switch > Component Information > Diagrams
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Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Specifications
Power Window Switch: Specifications
Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm
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Component Information > Diagrams > Power Window Switch
Power Window Switch: Diagrams Power Window Switch
2 Door
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Component Information > Diagrams > Power Window Switch > Page 11967
4 Door
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Component Information > Diagrams > Page 11968
Power Window Switch: Description and Operation
The window regulator control switch:
^ Is located on each door trim panel.
^ May be used to raise or lower both LH side and RH side windows from the master control on the
driver door.
^ Includes a window lock feature that is controlled through the master control.
^ Can manually lower the driver side window when the master control is depressed longer than 0.4
seconds.
^ The driver side window can be completely lowered when the master control is depressed
between 0.04 and 0.4 seconds and then released.
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Component Information > Testing and Inspection > Master Window Control Switch
Power Window Switch: Testing and Inspection Master Window Control Switch
Component Testing Procedure
Component Testing Procedure
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Terminals
Terminals
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Component Information > Testing and Inspection > Master Window Control Switch > Page 11972
Schematic
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Component Information > Testing and Inspection > Master Window Control Switch > Page 11973
Schematic
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Component Information > Testing and Inspection > Master Window Control Switch > Page 11974
Power Window Switch: Testing and Inspection Power window Switch
Right Front
Component Testing Procedure
Terminals
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Component Information > Testing and Inspection > Master Window Control Switch > Page 11975
Schematic
Left Rear
Component Testing Procedure
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Component Information > Testing and Inspection > Master Window Control Switch > Page 11976
Terminals
Schematic
Right Rear
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Component Information > Testing and Inspection > Master Window Control Switch > Page 11977
Component Testing Procedure
Terminals
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Schematic
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Component Information > Service and Repair > Driver Door
Power Window Switch: Service and Repair Driver Door
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the front door trim panel.
3. Remove the window regulator switch plate harness assembly.
1 Remove the screws.
2 Remove the harness assembly.
4. Remove the window regulator control switch.
1 Pry the release tabs.
2 Remove the window regulator control switch.
INSTALLATION
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1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Power Window Switch: Service and Repair Rear Door
REMOVAL
1. Remove the rear window regulator switch plate.
1 Remove the screws.
2 Remove the rear window regulator switch plate.
2. Remove the window regulator switch plate harness assembly.
1 Remove the screws.
2 Remove the harness assembly.
3. Remove the window regulator control switch.
1 Pry the release tabs.
2 Remove the window regulator control switch.
INSTALLATION
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Component Information > Service and Repair > Driver Door > Page 11983
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Locations
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information >
Diagrams > Diagram Information and Instructions
Power Window Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Power Window Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12000
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Diagrams > Diagram Information and Instructions > Page 12001
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Diagrams > Diagram Information and Instructions > Page 12002
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Diagrams > Diagram Information and Instructions > Page 12003
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information >
Diagrams > Page 12004
Power Window Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information >
Diagrams > Page 12005
Power Window Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Control Module > Component Information >
Diagrams > Page 12006
Power Window Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Specifications
Front Door Window Motor: Specifications
Power Window Motor Nuts 5.6-9.1 Nm
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Specifications > Page 12011
Front Door Window Motor: Service Precautions
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Specifications > Page 12012
Front Door Window Motor: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOLS
REMOVAL
1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3.
Disconnect the battery ground cable.
4. Disconnect the inside front door handle from the front door.
1 Remove the screws.
2 Disconnect the inside front door handle.
5. Disconnect the rod from the inside front door handle.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Specifications > Page 12013
6. Support the front door window glass.
7. If equipped, disconnect the power window motor electrical connector.
8. If equipped, remove the equalizer bracket to front door inner panel nuts.
9. Remove the window regulator/motor assembly.
1 Drill out the rivets.
2 Remove the nut.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Specifications > Page 12014
10. If equipped, remove the power window motor.
1 Remove the bolts.
2 Remove the power window motor.
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
INSTALLATION
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Specifications > Page 12015
1. To install, reverse the removal procedure.
^ Use Heavy Duty Riveter to install the new rivets.
^ Cycle the door glass to ensure engagement of the drive mechanism.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Specifications > Page 12016
Heavy Duty Riveter
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Specifications
Rear Door Window Motor: Specifications
Power Window Motor Nuts 5.6-9.1 Nm
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Specifications > Page 12020
Rear Door Window Motor: Service Precautions
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Specifications > Page 12021
Rear Door Window Motor: Service and Repair
REMOVAL
1. Raise and support the rear door window glass to the full up position. 2. Disconnect the battery
ground cable. 3. Remove the rear door trim panel.
4. Remove the speaker.
1 Remove the screws.
2 Disconnect the electrical connector.
3 Remove the speaker.
5. Remove the watershield.
6. Remove the power window motor.
1 Remove the bolts.
2 Disconnect the electrical connector.
3 Remove the power window motor.
INSTALLATION
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Specifications > Page 12022
1. To install, reverse the removal procedure.
^ Cycle the door glass to ensure engagement of the drive mechanism.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
miles) or more to relearn the strategy.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Rear Door Window Motor >
Component Information > Specifications > Page 12023
Heavy Duty Riveter
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations >
Page 12027
Power Window Relay: Description and Operation
LH Front Window Regulator Control Switch Inputs Table
The GEM controls manual down and OTD window movement with the OTD relay.
The relay is activated by applying ground directly to one side of the down window relay coil, and is
deactivated by removing the ground signal.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Locations >
Page 12028
Power Window Relay: Testing and Inspection
Component Testing Procedure
Terminals
Schematic
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information >
Specifications
Power Window Switch: Specifications
Rear Window Regulator Switch Plate Screws 1.4-2.0 Nm
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Power Window Switch
Power Window Switch: Diagrams Power Window Switch
2 Door
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Power Window Switch > Page 12034
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Power Window Switch > Page 12035
4 Door
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams
> Page 12036
Power Window Switch: Description and Operation
The window regulator control switch:
^ Is located on each door trim panel.
^ May be used to raise or lower both LH side and RH side windows from the master control on the
driver door.
^ Includes a window lock feature that is controlled through the master control.
^ Can manually lower the driver side window when the master control is depressed longer than 0.4
seconds.
^ The driver side window can be completely lowered when the master control is depressed
between 0.04 and 0.4 seconds and then released.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch
Power Window Switch: Testing and Inspection Master Window Control Switch
Component Testing Procedure
Component Testing Procedure
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch > Page 12039
Terminals
Terminals
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch > Page 12040
Schematic
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch > Page 12041
Schematic
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch > Page 12042
Power Window Switch: Testing and Inspection Power window Switch
Right Front
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch > Page 12043
Schematic
Left Rear
Component Testing Procedure
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch > Page 12044
Terminals
Schematic
Right Rear
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch > Page 12045
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Master Window Control Switch > Page 12046
Schematic
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service
and Repair > Driver Door
Power Window Switch: Service and Repair Driver Door
REMOVAL
1. Disconnect the battery ground cable. 2. Remove the front door trim panel.
3. Remove the window regulator switch plate harness assembly.
1 Remove the screws.
2 Remove the harness assembly.
4. Remove the window regulator control switch.
1 Pry the release tabs.
2 Remove the window regulator control switch.
INSTALLATION
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service
and Repair > Driver Door > Page 12049
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service
and Repair > Driver Door > Page 12050
Power Window Switch: Service and Repair Rear Door
REMOVAL
1. Remove the rear window regulator switch plate.
1 Remove the screws.
2 Remove the rear window regulator switch plate.
2. Remove the window regulator switch plate harness assembly.
1 Remove the screws.
2 Remove the harness assembly.
3. Remove the window regulator control switch.
1 Pry the release tabs.
2 Remove the window regulator control switch.
INSTALLATION
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Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service
and Repair > Driver Door > Page 12051
1. To install, reverse the removal procedure.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair
Front Door Window Glass: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the front door trim panel.
2. Remove the inside glass weatherstrip.
3. Drill out the window regulator arm to window glass rivets.
NOTE: Lower the window glass to access the two rivets.
4. Remove the front door window glass.
NOTE: Slide the glass through the outboard side of the front door.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > System
Information > Service and Repair > Page 12056
INSTALLATION
1. Position the front door window glass.
NOTE: Slide the glass through the outboard side of the front door.
2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets.
3. Install the inside glass weatherstrip. 4. Install the front door trim panel.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair
Liftgate Window Glass: Service and Repair
REMOVAL
1. Open the liftgate glass.
2. Disconnect the two rear window defogger electrical connectors (one on each side).
3. Disconnect the two liftgate cylinders (one on each side).
4. Release the upper liftgate trim panel clips to gain access to liftgate window glass access plugs.
5. Remove the liftgate glass hinge access plugs.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Liftgate Window Glass > Component
Information > Service and Repair > Page 12060
6. Remove the liftgate window glass.
1 Remove the two liftgate window glass to window hinge nuts.
2 Remove the liftgate window glass.
INSTALLATION
1. To install, reverse the removal procedure.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Movable Quarter
Quarter Window Glass: Service and Repair Movable Quarter
REMOVAL
1. Remove the quarter trim panel. 2. Remove the quarter window glass.
1 Remove the nuts.
2 Remove the quarter window glass.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: If the seal requires adjustment, disconnect the quarter trim panel. Rotate the quarter
window latch clockwise to increase seal pressure or counterclockwise to reduce seal pressure.
Reconnect the quarter window latch.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component
Information > Service and Repair > Movable Quarter > Page 12065
Quarter Window Glass: Service and Repair Quarter
REMOVAL
1. Remove the quarter trim panel.
2. Remove the rear quarter window glass.
1 Remove the ten nuts.
2 Carefully push the rear quarter window glass outward to release the butyl seal.
3. Remove the excess foam butyl from the window opening.
INSTALLATION
1. Apply 6 mm (0.23 in) foam butyl or equivalent meeting Ford specification WSB-M2G234-C to the
rear quarter window glass frame.
^ Start at the bottom middle and work around the frame.
NOTE: When applying foam butyl, leave a slight overlap at the bottom to allow for drainage.
2. Install the rear quarter window glass.
1 Position the rear quarter window glass.
2 Tighten the ten nuts to specification.
NOTE: Loosely install the ten nuts before tightening.
3. Install the quarter trim panel.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair
Rear Door Window Glass: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOL(S)
REMOVAL
1. Remove the rear door trim panel.
2. Remove the inside glass weatherstrip.
3. Drill out the window regulator arm to window glass rivets.
4. Remove the rear door window glass.
NOTE: Slide the glass through the outboard side of the rear door.
INSTALLATION
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Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > System
Information > Service and Repair > Page 12069
1. Position the rear door window glass.
NOTE: Slide the glass through the outboard side of the rear door.
2. Use Heavy Duty Riveter to install the window regulator arm to window glass rivets.
3. Install the inside glass weatherstrip. 4. Install the rear door trim panel.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Specifications
Front Door Window Regulator: Specifications
Rear Window Glass Regulator Nut 10-14 Nm
Window Regulator Switch Plate Harness Assembly 2-3 Nm
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Specifications > Page 12074
Front Door Window Regulator: Service Precautions
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Specifications > Page 12075
Front Door Window Regulator: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOLS
Motor and Window Regulator - Front Door
REMOVAL
1. Raise the front door window glass to the full up position. 2. Remove the front door trim panel. 3.
Disconnect the battery ground cable.
4. Disconnect the inside front door handle from the front door.
1 Remove the screws.
2 Disconnect the inside front door handle.
5. Disconnect the rod from the inside front door handle.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Specifications > Page 12076
6. Support the front door window glass.
7. If equipped, disconnect the power window motor electrical connector.
8. If equipped, remove the equalizer bracket to front door inner panel nuts.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Specifications > Page 12077
9. Remove the window regulator/motor assembly.
1 Drill out the rivets.
2 Remove the nut.
10. If equipped, remove the power window motor.
1 Remove the bolts.
2 Remove the power window motor.
WARNING: PRIOR TO POWER WINDOW REMOVAL, ENSURE THE REGULATOR ARMS ARE
IN A FIXED POSITION TO PREVENT COUNTERBALANCE SPRING UNWIND. FAILURE TO
PLACE THE REGULATOR ARMS IN A FIXED POSITION CAN CAUSE THE SPRING TO
SUDDENLY RELEASE RESULTING IN PERSONAL INJURY.
INSTALLATION
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Specifications > Page 12078
1. To install, reverse the removal procedure.
^ Use Heavy Duty Riveter to install the new rivets.
^ Cycle the door glass to ensure engagement of the drive mechanism.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System
Information > Specifications > Page 12079
Heavy Duty Riveter
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Specifications
Rear Door Window Regulator: Specifications
Rear Window Glass Regulator Nut 10-14 Nm
Window Regulator Switch Plate Harness Assembly 2-3 Nm
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Specifications > Page 12083
Rear Door Window Regulator: Service and Repair
Heavy Duty Riverter
SPECIAL SERVICE TOOLS
REMOVAL
1. Remove the rear door trim panel.
2. Disconnect the inside rear door handle from the rear door.
1 Remove the screws.
2 Disconnect the inside rear door handle.
3. Disconnect the rod from the inside rear door handle.
4. Remove the speaker.
1 Remove the screws.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Specifications > Page 12084
2 Disconnect the electrical connector.
3 Remove the speaker.
5. Remove the watershield. 6. Raise and support the rear door window glass to the full up position.
7. Disconnect the battery ground cable.
8. If equipped, disconnect the power window electrical connector.
9. Drill out the window regulator rivets.
10. Remove the rear door window regulator.
^ Slide the regulator arms off of the window glass track.
INSTALLATION
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Specifications > Page 12085
1. To install, reverse the removal procedure.
^ Use Heavy Duty Riveter to install the new rivets.
^ Cycle the door glass to ensure engagement of the drive mechanism.
NOTE: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10
mi) or more to relearn the strategy.
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Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System
Information > Specifications > Page 12086
Heavy Duty Riveter
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Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician
Safety Information
Windshield: Technician Safety Information
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING
HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM
THE VEHICLE.
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Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Service Precautions > Technician
Safety Information > Page 12091
Windshield: Vehicle Damage Warnings
CAUTION:
^ If the vehicle is to be driven within 24 hours of urethane application, urethane sealant Essex
U-216 must be used due to its one hour cure time.
^ After installing the urethane installed glass, the vehicle should not be driven until the urethane
has cured. The curing times at temperatures above 13°C (55°F) and relative humidity above 50%
is 12 - 24 hours (decreasing at higher temperatures and lower humidities). Inadequate curing of the
urethane may adversely affect the strength of the urethane bond.
^ Do not scratch the pinch weld area.
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Windshield: Description and Operation
Windshield Glass
The windshield glass: ^
Is standard plastic and glass laminate safety glass.
^ Is bonded to the window opening flange with urethane sealant.
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Windshield: Service and Repair
SPECIAL SERVICE TOOLS
REMOVAL
WARNING: TO PREVENT GLASS SPLINTERS FROM ENTERING THE EYES OR CUTTING
HANDS, WEAR SAFETY GLASSES AND HEAVY GLOVES WHEN CUTTING THE GLASS FROM
THE VEHICLE.
1. Remove the windshield side garnish moldings. 2. Remove the interior rear view mirror. For
additional information, refer to Mirrors. 3. If equipped, remove the overhead console. Refer to
Interior Trim.
4. Remove the sun visors.
1 Remove the sun visor screws.
2 Remove the sun visors.
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^ If equipped, disconnect the electrical connector.
5. Remove the sun visor clips.
1 Remove the sun visor clip screws.
2 Remove the sun visor clips.
6. Lower the front portion of the headliner. 7. Remove the cowl grille.
8. Remove the upper windshield weatherstrip.
9. Remove the LH and RH windshield mouldings.
10. Using a soft brush or vacuum, remove any dirt or foreign material from the pinch weld.
11. Using the special tool, cut the urethane sealant from the windshield glass starting at the top
center and work toward the bottom corners.
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NOTE: Lubricate the urethane sealant with water to aid the special tool when cutting.
12. Using the special tool, distance the windshield from the body.
13. Using the special tool, cut the remaining urethane sealant and remove the windshield glass. 14.
Using a soft brush or vacuum, remove any foreign material or dirt from the pinch weld.
INSTALLATION
CAUTION: After installing the urethane installed glass, the vehicle should not be driven until the
urethane has cured. The curing times at temperatures above 13°C (55°F) and relative humidity
above 50% is 12 - 24 hours (decreasing at higher temperatures and lower humidities). Inadequate
curing of the urethane may adversely affect the strength of the urethane bond.
1. Dry fit the windshield. Make alignment marks with tape or non-staining grease pencil.
2. Trim the remaining urethane sealant on the pinch weld to within the specification.
^ The existing urethane sealant surface should be smooth and free of cuts and contamination.
CAUTION: Do not scratch the pinch weld area.
3. Use a wool applicator to apply Urethane Metal Primer Essex U-413 meeting Ford specification
WSB-M2G234-C to any exposed metal on the
pinch weld. Allow six to ten minutes to dry.
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4. Apply (A) Foam Butyl meeting Ford specification WSB-M2G234-C to the (B) pinch weld. 5. If
reinstalling original windshield, remove the excess urethane sealant from the windshield glass. 6.
Clean the inside of the glass surface with an alcohol-free cleaner making sure the ceramic coated
area is clean. 7. Apply Urethane Glass Prep Essex U-401 meeting Ford specification
WSB-M2G314-B twice around the glass surface to be urethaned.
NOTE: Wipe off the Glass Prep immediately after each application because it flash dries.
8. Apply Glass Primer Essex U-402 meeting Ford specification WSB-M5B280-C to the same area
that was prepped in the pervious step. Allow five
minutes to dry.
9. Cut the urethane applicator tip to specification.
10. Apply a bead of urethane sealant Essex 400-HV or Essex U-216, which meets Ford
specification WSB-M2G316-B to the pinch weld just outside
the foam dam.
CAUTION: If the vehicle is to be driven within 24 hours of urethane application, urethane sealant
Essex U-216 must be used due to its one hour cure time.
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11. Install the windshield glass aligning it to the marks previously made. 12. After the windshield
glass is set , check for water leaks and add urethane sealant where needed.
13. Install the upper windshield weatherstrip. 14. If necessary, remove excess urethane from the
outside surface of the windshield glass.
15. Install the LH and RH windshield mouldings. 16. Install the cowl grille. 17. If equipped, install
the overhead console.
18. Install the sun visor clips.
1 Install the sun visor clips.
2 Install the screws.
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19. Install the sun visors.
1 Install the sun visors. ^
If equipped, connect the electrical connector.
2 Install the screws.
20. Install the front portion of the headliner. 21. Install the interior rear view mirror. For additional
information, refer to Mirrors.
22. Install the windshield side garnish mouldings.
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Windshield: Tools and Equipment
SPECIAL SERVICE TOOLS
Foam Butyl ..........................................................................................................................................
........................................................ WSB-M2G234-C Urethane Glass Prep Essex U-401
..............................................................................................................................................................
WSB-M2G314-B Urethane Glass Primer Essex U-402
...........................................................................................................................................................
WSB-M5B280-C Urethane Metal Primer Essex U-413
..........................................................................................................................................................
WSB-M2G234-C Urethane Sealant Essex U-216 ...............................................................................
..................................................................................... WSB-M2G316-B Urethane Sealant Essex
400-HV ................................................................................................................................................
................. WSB-M2G316-B
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Check Valve, Washer > Component Information > Locations
Rear Wiper And Washer System
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions
Windshield Washer Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12110
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12111
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12112
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12113
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12114
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12115
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12116
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12117
Windshield Washer Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12118
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12119
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12120
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12121
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12122
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12123
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Page 12124
Windshield Washer Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
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Washer Control Module > Component Information > Diagrams > Page 12125
Windshield Washer Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Control Module > Component Information > Diagrams > Page 12126
Windshield Washer Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Locations > Front Washer Pump Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Locations > Front Washer Pump Relay > Page 12131
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield
Washer Relay > Component Information > Locations > Page 12132
Windshield Washer Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Micro ISO Relay
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Washer Relay > Component Information > Locations > Page 12133
Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts
position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If
battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to
a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace
the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions
Wiper Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12139
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12140
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12141
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12142
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12143
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12144
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12145
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12146
Wiper Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12147
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12148
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12149
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
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Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12150
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12151
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12152
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Control Module > Component Information > Diagrams > Page 12153
Wiper Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
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Control Module > Component Information > Diagrams > Page 12154
Wiper Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
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Control Module > Component Information > Diagrams > Page 12155
Wiper Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
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Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay
> Component Information > Locations > Rear Wiper Up Relay
Wiper Relay: Locations Rear Wiper Up Relay
Part (1 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12160
Part (2 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12161
Wiper Relay: Locations Rear Wiper Down Relay
Part (1 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12162
Part (2 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12163
Wiper Relay: Locations Wiper High Relay
Part (1 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12164
Part (2 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12165
Wiper Relay: Locations Wiper Low Relay
Part (1 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12166
Part (2 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12167
Wiper Relay: Locations Wiper Park Relay
Part (1 Of 2)
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> Component Information > Locations > Rear Wiper Up Relay > Page 12168
Part (2 Of 2)
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> Component Information > Locations > Page 12169
Wiper Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Micro ISO Relay
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> Component Information > Locations > Page 12170
Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts
position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If
battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to
a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace
the relay.
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Specifications
Windshield Washer Switch: Specifications
Windshield Wiper Washer Switch 2-3 Nm
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Washer Switch > Component Information > Specifications > Page 12175
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Multifunction Switch
Windshield Washer Switch: Diagrams Multifunction Switch
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
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Washer Switch > Component Information > Diagrams > Multifunction Switch > Page 12178
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 12179
Windshield Washer Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
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Washer Switch > Component Information > Diagrams > Page 12180
Component Testing Procedure
Terminals
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Washer Switch > Component Information > Diagrams > Page 12181
Schematic
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Washer Switch > Component Information > Diagrams > Page 12182
Schematic
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Diagrams > Page 12183
Windshield Washer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
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Washer Switch > Component Information > Diagrams > Page 12184
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Locations
Wiper Switch: Locations
Rear Wiper And Washer System
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Switch > Component Information > Locations > Page 12188
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Diagrams > Multifunction Switch
Wiper Switch: Diagrams Multifunction Switch
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
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Switch > Component Information > Diagrams > Multifunction Switch > Page 12191
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Switch > Component Information > Diagrams > Page 12192
Wiper Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
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Switch > Component Information > Diagrams > Page 12193
Component Testing Procedure
Terminals
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Switch > Component Information > Diagrams > Page 12194
Schematic
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Switch > Component Information > Diagrams > Page 12195
Schematic
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Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Service and Repair > Rear Wiper Switch
Wiper Switch: Service and Repair Rear Wiper Switch
REMOVAL
1. Remove the instrument panel finish panel.
1 Remove the two screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
2. Remove the rear wiper/washer switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the rear wiper/washer switch.
INSTALLATION
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Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 12198
1. To install, reverse the removal procedure.
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Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 12199
Wiper Switch: Service and Repair Multifunction Switch
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
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Switch > Component Information > Service and Repair > Rear Wiper Switch > Page 12200
2 Remove the upper and lower steering column shrouds.
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information >
Description and Operation
Washer Fluid Level Indicator: Description and Operation
This warning message is displayed when there is less than one quarter of the container of washer
fluid remaining
^ When the washer fluid level is normal, the windshield washer reservoir fluid level sensor will
close, grounding the input Circuit 82 (PK/YE) at C200931 of the message center indicator.
^ When the washer fluid level is low, the input to the message center indicator will be open and the
warning will be displayed.
The message center indicator filters this input therefore, there will be a 20-second delay before the
warning is displayed or removed.
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions
Windshield Washer Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Diagrams > Diagram Information and Instructions > Page 12209
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Diagrams > Diagram Information and Instructions > Page 12210
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Diagrams > Diagram Information and Instructions > Page 12211
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
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Diagrams > Diagram Information and Instructions > Page 12212
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
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Diagrams > Diagram Information and Instructions > Page 12213
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12214
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Diagrams > Diagram Information and Instructions > Page 12215
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12216
Windshield Washer Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12217
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12218
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12219
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12220
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12221
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 12222
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Page 12223
Windshield Washer Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Page 12224
Windshield Washer Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Control Module > Component Information >
Diagrams > Page 12225
Windshield Washer Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations
Rear Washer Hose Location And Routing
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations >
Page 12229
Windshield Washer Hose: Description and Operation
Wipers and Washers-Rear Washer Hose
Fluid for the rear washer is supplied by a two-way washer pump located in the windshield washer
fluid reservoir in the engine compartment.
The rear washer hose contains a check valve, which is located in the hose that passes through the
liftgate in the rear of the vehicle. This check valve holds the entire line full of washer fluid between
washer operation. There is also a stand pipe located along the right hand D-pillar of the vehicle.
This stand pipe prevents the unintentional release of washer fluid from the rear washer nozzle. If
the hose is cut or disconnected after the line was initially primed with fluid, and the washer system
is turned on, the stand pipe may fill with fluid. To resolve this, once the hose is repaired,
temporarily disconnect the check valve to allow fluid in stand pipe to drain to lowest point in the
hose; then reinstall the check valve.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Locations >
Page 12230
Windshield Washer Hose: Service and Repair
1. Locate and verify the leaking washer hose.
2. Cut the hose cleanly and remove the damaged portion of the washer hose. 3. Install a
windshield washer hose adapter between the cut ends of the hose. 4. Install a segment of 6.4 mm
(0.25 in) i.d. black rubber hose N809610-S or equivalent over the ends of the washer hose, and
clamp both ends of
the rubber hose using spring clamps 389252-S101 or equivalent.
NOTE: In difficult cases, clamping may be required.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations
Wiper And Washer Systems
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations
> Page 12234
Windshield Washer Pump: Service and Repair
REMOVAL
1. Disconnect the windshield washer hose from the windshield washer pump.
NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before
removal.
2. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the
outlet of the reservoir.
3. Disconnect the windshield washer reservoir pump electrical connector and low level washer fluid
electronic sensor connector, if equipped. 4. Remove the engine air cleaner; refer to Fuel Delivery
and Air Induction.
5. Remove the two screws and two nuts and remove the windshield washer reservoir.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Locations
> Page 12235
6. Remove the windshield washer pump.
NOTE: Make sure not to tear the rubber grommet during disassembly.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The windshield washer reservoir, windshield washer pump and the windshield washer
reservoir fluid level sensor are replaced separately.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations >
Front Washer Pump Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations >
Front Washer Pump Relay > Page 12240
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations >
Page 12241
Windshield Washer Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Micro ISO Relay
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Locations >
Page 12242
Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts
position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If
battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to
a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace
the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Specifications
Windshield Washer Reservoir: Specifications
Windshield Wiper/Washer Reservoir Screw and Nut 5-6 Nm
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Specifications > Page 12246
Wiper And Washer Systems
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Specifications > Page 12247
Windshield Washer Reservoir: Service and Repair
REMOVAL
1. Disconnect the windshield washer hose from the windshield washer pump.
NOTE: To prevent spilling windshield washer fluid, drain the windshield washer reservoir before
removal.
2. Disconnect the coolant overflow hose from the engine coolant overflow reservoir and plug the
outlet of the reservoir.
3. Disconnect the windshield washer reservoir pump electrical connector and low level washer fluid
electronic sensor connector, if equipped. 4. Remove the engine air cleaner; refer to Fuel Delivery
and Air Induction.
5. Remove the two screws and two nuts and remove the windshield washer reservoir.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Specifications > Page 12248
6. Remove the windshield washer pump.
NOTE: Make sure not to tear the rubber grommet during disassembly.
INSTALLATION
1. To install, reverse the removal procedure.
NOTE: The windshield washer reservoir, windshield washer pump and the windshield washer
reservoir fluid level sensor are replaced separately.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information >
Locations
Windshield Washer Spray Nozzle: Locations
Rear Wiper And Washer System
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Spray Nozzle > Component Information >
Locations > Page 12252
Wiper And Washer Systems
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Specifications
Windshield Washer Switch: Specifications
Windshield Wiper Washer Switch 2-3 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information >
Specifications > Page 12256
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Multifunction Switch
Windshield Washer Switch: Diagrams Multifunction Switch
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Multifunction Switch > Page 12259
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Page 12260
Windshield Washer Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Page 12261
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Page 12262
Schematic
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Page 12263
Schematic
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Page 12264
Windshield Washer Switch: Service and Repair
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.
2 Remove the upper and lower steering column shrouds.
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Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams
> Page 12265
5. Remove the multi-function switch.
1 Remove the screws.
2 Disconnect the electrical connectors.
3 Remove the multi-function switch.
Installation
1. Note: When the battery is disconnected and reconnected, some abnormal drive symptoms may
occur while the vehicle relearns its adaptive
strategy. The vehicle may need to be driven 16 km (10 mi) or more to relearn the strategy.
To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications
Wiper Arm: Specifications
PivotArm-RearNut 13-17 Nm
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page
12269
Wiper Arm: Locations
Rear Wiper And Washer System
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page
12270
Wiper And Washer Systems
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Specifications > Page
12271
Wiper Arm: Service Precautions
CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the
procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot
Arm-Front
Wiper Arm: Service and Repair Pivot Arm-Front
REMOVAL
1. Remove the pivot arm.
1 Pull upon the pivot arm.
2 Pull out on the retainer tab and remove the pivot arm.
NOTE: The windshield wiper pivot arms are replaced as an assembly.
INSTALLATION
1. To install. reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot
Arm-Front > Page 12274
Wiper Arm: Service and Repair Pivot Arm-Rear
REMOVAL
CAUTION: Use a shop towel or similar device to protect the vehicle finish when performing the
procedure.
1. Disconnect the rear washer hose.
2. Remove rear pivot arm.
1 Lift the pivot arm nut cover.
2 Remove the nut.
3 Remove the pivot arm.
INSTALLATION
1. Turn the rear wiper switch on and allow the motor to operate for at least one cycle.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot
Arm-Front > Page 12275
2. Turn the rear wiper switch OFF.
NOTE: This step ensures that the wiper motor is in the park position.
3. Position the wiper blade outside the wiper arm stop.
4. Install the wiper pivot arm onto the wiper motor.
^ Tighten retaining nut.
5. Connect the washer hose.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Pivot
Arm-Front > Page 12276
6. Cycle the wiper motor one time to allow the wiper arm to park on the wiper arm stop.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Locations
Wiper Blade: Locations
Wiper And Washer Systems
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Locations > Page 12280
Rear Wiper And Washer System
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions
Wiper Control Module: Diagram Information and Instructions
How to Find and Use These Diagrams
Diagrams are presented in three main categories:
^ Power Distribution Diagrams
^ System Diagrams
^ Grounds Diagrams
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12286
Diagram 13-7 (Sample Power Distribution Diagram Page)
Power Distribution Diagrams Provide the circuit details of how the system diagrams are powered.
The power distribution source is shown at the top of a diagram page. All wires, connectors, and
splices are shown in the same manner that the current flows, ending at the component/system
being powered near the bottom of a diagram page. Circuits that go from one diagram page to
another will be marked with large arrow heads indicating which diagram page the circuit went
to/came from.
The power distribution diagrams can be found at Starting and Charging/Power and Ground
Distribution, or by following the hyperlinks at the top of the
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Diagram Information and Instructions > Page 12287
diagram pages within the system diagrams.
Diagram 85-1 (Sample System Diagram Page)
System Diagrams Components that work together are shown together in a system/subsystem
diagram or set of diagrams. The system feed (circuit breaker, fuse, etc.) is shown at the top of a
diagram page. All wires, connectors, components, and splices are shown in the same manner that
the current flows, ending at the ground at the bottom of a diagram page. Circuits that go from one
diagram page to another will be marked with large arrow heads indicating which diagram page the
circuit went to/came from.
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12288
Diagram 10-1 (Sample Grounds Diagram Page)
Grounds Diagrams Provide the circuit details of how the system diagrams are grounded. This
information is useful for checking interconnections of the grounding circuits of different systems.
The components/systems being grounded are shown at the top of a diagram page. All wires,
connectors, and splices are shown in the same manner that the current flows, ending at the ground
at the bottom of a diagram page. Circuits that go from one diagram page to another will be marked
with large arrow heads indicating which diagram page the circuit went to/came from.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12289
The grounds diagrams can be found at Starting and Charging/Power and Ground Distribution, or by
following the hyperlinks at the bottom of the diagram pages within the system diagrams.
Component Identification Information
Component Identification Information consists of
(1) A-Z Component List, (2) Component Location Views, and (3) Connector views (Faces).
The A-Z Component List helps the user find where the various items depicted on the diagram can
physically be found on the vehicle. A brief written description of the location is given. See:
Locations/Component Locations/A-Z Component List
The Component Location Views show the components and their connecting wires as they can be
found on the vehicle. See: Locations/Component Locations/Component Location Views
The Connector Views show the views of the pins and/or cavities of all connectors. The pin and
cavity sides are shown separately as if the connector were disconnected. The color of the
connector housing is indicated next to the connector number. See: Diagrams/Connector Views
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12290
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12291
Electrical Symbols
Wire Color Code Identification
Wire and connector colors are listed as follows (standard Ford color abbreviations are used):
COLOR ABBREVIATIONS BU
Blue NA Natural
BK Black OG Orange
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12292
BN Brown PK Pink
DB Dark Blue VT Purple
DG Dark Green RD Red
GN Green SR Silver
GY Gray TN Tan
LB Light Blue WH White
LG Light Green YE Yellow
Note: Whenever a wire is labeled with two colors, the first color listed is the basic color of the wire,
and the second color listed is the stripe marking of the wire.
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12293
Wiper Control Module: Diagnostic Aids
HOW TO FIND ELECTRICAL CONCERNS
TROUBLESHOOTING STEPS
These six steps present an orderly method of troubleshooting.
Step 1. Verify the concern.
^ Operate the complete system to check the accuracy and completeness of the customer's
complaint.
Step 2. Narrow the concern.
^ Using the wiring diagrams, narrow down the possible causes and locations of the concern to
pinpoint the exact cause.
^ Read the description notes at the components and study the wiring schematic. You should then
know enough about the circuit operation to determine where to check for the trouble.
Step 3. Test the suspected cause.
^ Use electrical test procedures to find the specific cause of the symptoms.
^ The component location reference bars and the pictures will help you find components.
Component location information for connectors, diodes, resistors, splices and grounds can be
found at Vehicle Locations.
Step 4. Verify the cause.
^ Confirm that you have found the correct cause by connecting jumper wires and/or temporarily
installing a known good component and operating the circuit.
Step 5. Make the repair.
^ Repair or replace the inoperative component.
Step 6. Verify the repair.
^ Operate the system as in Step 1 and check that your repair has removed all symptoms without
creating any new symptoms.
Some engine circuits may need special test equipment and special procedures. See Testing and
Inspection for the specific component, system, or sub-system in question.
NOTE: Most Ford testing and inspection procedures will be found at the system/sub-system level;
only a few component tests are provided by OE.
TROUBLESHOOTING TOOLS
JUMPER WIRE
This is a test lead used to connect two points of a circuit. A Jumper Wire can bypass an open to
complete a circuit.
WARNING: Never use a jumper wire across loads (motors,etc.) connected between hot and
ground. This direct battery short may cause injury or fire.
VOLTMETER
A DC Voltmeter measures circuit voltage. Connect negative (- or black) lead to ground, and
positive (+ or red) lead to voltage measuring point.
OHMMETER
An Ohmmeter shows the resistance between two connected points.
TEST LAMP
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12294
A Test Light is a 12-volt bulb with two test leads. Uses: Voltage Check, Short Check.
SELF-POWERED TEST LAMP
The Self-Powered Test Lamp is a bulb, battery and set of test leads wired in series. When
connected to two points of a continuous circuit, the bulb glows. Uses: Continuity Check, Ground
Check.
CAUTION: When using a self -powered test lamp or ohmmeter; be sure power is off in circuit
during testing. Hot circuits can cause equipment damage and false readings.
In an inoperative circuit with a switch in series with the load, jumper the terminals of the switch to
power the load. If jumpering the terminals powers the circuit, the switch is inoperative.
CONTINUITY CHECK (Locating open circuits)
Connect one lead of Self-Powered Test Lamp or Ohmmeter to each end of circuit. Lamp will glow if
circuit is closed. Switches and fuses can be checked in the same way.
VOLTAGE CHECK
Connect one lead of test lamp to a known good ground or the negative (-) battery terminal. Test for
voltage by touching the other lead to the test
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12295
point. Bulb goes on when the test point has voltage.
SHORT CHECK
A fuse that repeatedly blows is usually caused by a short to ground. It's important to be able to
locate such a short quickly. 1. Turn off everything powered through the fuse. 2. Disconnect other
loads powered through the fuse:
^ Motors: disconnect motor connector (Connector C4).
^ Lights: remove bulbs.
3. Turn Ignition Switch to RUN (if necessary) to power fuse. 4. Connect one Test Lamp lead to hot
end of blown fuse. Connect other lead to ground. Bulb should glow, showing power to fuse. This
step is
just a check to be sure you have power to the circuit)
5. Disconnect the test lamp lead that is connected to ground, and reconnect it to the load side of
the fuse at the connector of the disconnected
component. (Connect the test lamp lead to connector C4). ^
If the Test Lamp is off, the short is in the disconnected component.
^ If the Test Lamp goes on, the short is in the wiring. You must find the short by disconnecting the
circuit connectors, one at a time, until the Test Lamp goes out. For example, with a ground at X,
the bulb goes out when C1 or C2 is disconnected, but not after disconnecting C3. This means the
short is between C2 and C3.
GROUND CHECK
Turn on power to the circuit. Perform a Voltage Check between the suspected inoperative ground
and the frame. Any indicated voltage means that the ground is inoperative.
Turn off power to the circuit. Connect one lead of a Self-Powered Test Lamp or Ohmmeter to the
wire in question and the other lead to a known ground. If the bulb glows, the circuit ground is OK.
DIAGRAMS These diagrams make it easy to identify common points in circuits. This knowledge
can help narrow the concern to a specific area. For example, if several circuits fail at the same
time, check for a common power or ground connection (see Power and Ground Distribution
Diagrams). If part of a
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12296
circuit fails, check the connections between the part that works and the part that doesn't work.
For example, if the lo beam headlamps work, but the high beams and the indicator lamp don't
work, then power and ground paths must be good. Since the dimmer switch is the component that
switches this power to the high beam lights and indicator, it is most likely the cause of failure.
TROUBLESHOOTING WIRING HARNESS AND CONNECTOR HIDDEN CONCERNS
The following illustrations are known examples of wiring harness, splices and connectors that will
create intermittent electrical concerns. The concerns are hidden and can only be discovered by a
physical evaluation as shown in each illustration.
NOTE: Several components, such as the PCM, utilize gold plated terminals in their connections to
the wiring harness. If those terminals need to be replaced, they must be replaced with a gold plated
terminal.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12297
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12298
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Diagram Information and Instructions > Page 12299
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Page 12300
Wiper Control Module: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Page 12301
Wiper Control Module: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Diagrams >
Page 12302
Wiper Control Module: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications
Wiper Motor: Specifications
Rear Wiper Motor Bolts 9-12 Nm
Windshield Wiper Motor Bolts 7.0-9.0 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page
12306
Wiper Motor: Locations
Wiper And Washer Systems
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page
12307
Rear Wiper And Washer System
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12308
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page
12309
Wiper Motor: Service Precautions
CAUTION:
^ Do not handle the wiper motor abusively when diagnosing the wiper operations. Failure to follow
this caution may result in damage to the motor magnets and will make the wiper motor inoperative.
Rough handling of new replacement wiper motors may also damage the motor magnets.
^ The internal permanent magnets used in the windshield wiper motor are made of a glass-like
material. To avoid damaging the magnets, do not strike the motor with a hammer or any other
object.
^ To avoid possible damage to the mounting arm and pivot shaft retainer clip, be sure the clip is
fully seated before installing on the motor crank pin.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Specifications > Page
12310
Wiper Motor: Testing and Inspection
CAUTION: Do not handle the wiper motor abusively when diagnosing the wiper operations. Failure
to follow this caution may result in damage to the motor magnets and will make the wiper motor
inoperative. Rough handling of new replacement wiper motors may also damage the motor
magnets.
Use Alternator, Regulator, Battery and Starter Tester (ARBST) to test the wiper motor on the
vehicle.
To test the wiper motor, disconnect the windshield wiper mounting arm and pivot shaft from the
windshield wiper motor; refer to Pivot Arm-Front or Pivot Arm-Rear.
Disconnect the wiper motor. Connect the (1) green lead from (2) Alternator, Regulator, Battery and
Starter Tester (ARBST) to the battery negative (-) post. Connect the (3) red lead from ARBST to
the wiper motor (4) common brush terminal (terminal 3).
Test the low speed mode by connecting a (5) cable from the battery positive (+) post to the (6) low
speed brush terminal (terminal 4) and measure the current draw. If the current draw is greater than
3.5 amperes, replace the windshield wiper motor.
Test the high speed mode by connecting a cable from the battery positive (+) post to the (7) high
speed brush terminal (terminal 5) and measure the current draw. If the current draw is greater than
5.5 amperes, replace the wiper motor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor
Wiper Motor: Service and Repair Windshield Wiper Motor
REMOVAL
CAUTION: The internal permanent magnets used in the windshield wiper motor are made of a
glass-like material. To avoid damaging the magnets, do not strike the motor with a hammer or any
other object.
NOTE: The windshield wiper motor is not a repairable item. If worn or damaged, the motor must be
replaced.
1. Remove the LH pivot arm.
1 Pull upon the pivot arm.
2 Pull out on the retainer tab and remove the pivot arm.
2. Remove the LH cowl top vent panel screw.
3. Disconnect the washer hose from the LH washer jet nozzle.
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 12313
4. Remove the LH cowl top vent panel. Release the seven spring retainers.
5. Unsnap the wiper motor clip from the RH mounting arm and pivot shaft.
6. Disconnect the RH windshield wiper mounting arm and pivot shaft from the LH windshield wiper
mounting arm and pivot shaft and move both
away from the windshield wiper motor.
7. Disconnect the electrical connector.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 12314
8. Remove the ground strap nut and position the strap aside.
9. Remove the windshield wiper motor.
^ Remove the stud bolts.
^ Remove the bolts.
INSTALLATION
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 12315
1. To install, reverse the removal procedure.
CAUTION: To avoid possible damage to the mounting arm and pivot shaft retainer clip, be sure the
clip is fully seated before installing on the motor crank pin.
NOTE: ^
Install the LH mounting arm and pivot shaft to the motor before installing the RH mounting arm and
pivot shaft.
^ Install the retainer clip on the RH mounting arm and pivot shaft prior to installing the motor.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Windshield Wiper Motor > Page 12316
Wiper Motor: Service and Repair Rear Wiper Motor
REMOVAL
1. Remove the rear pivot arm; refer to Pivot Arm-Rear. 2. Remove the liftgate door trim panel. 3.
Position the watershield aside to gain access to the rear wiper motor.
4. Remove rear wiper motor.
^ Disconnect electrical connector.
^ Remove three retaining bolts.
^ Remove rear wiper motor.
INSTALLATION
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications
Wiper Motor Linkage: Specifications
Windshield Wiper Pivot Shaft Nut 10-13 Nm
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications >
Page 12320
Wiper Motor Linkage: Service Precautions
CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be
sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield
wiper motor crank pin.
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications >
Page 12321
Wiper Motor Linkage: Service and Repair
REMOVAL
1. Cycle the windshield wiper blades to the vertical position. 2. Remove the cowl top vent panels.
3. Unsnap the wiper motor clip from the RH mounting arm and pivot shaft.
4. Disconnect the RH windshield wiper mounting arm and pivot shaft from the LH windshield wiper
mounting arm and pivot shaft and move both
away from the windshield wiper motor.
5. Remove the RH and LH mounting arm and pivot shafts.
1 Remove the two nuts.
2 Remove the mounting arm and pivot shafts.
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Specifications >
Page 12322
INSTALLATION
1. Install the RH and LH mounting arms and pivot shafts.
1 Position the mounting arm and pivot shafts into place.
2 Install the two nuts.
2. Install the clip onto the RH mounting arm and pivot shaft.
CAUTION: To avoid possible damage to the windshield wiper adapter and connecting arm clip, be
sure the clip is fully seated before installing the adapter and connecting arm clip on the windshield
wiper motor crank pin.
3. Install the LH windshield wiper mounting arm and pivot shaft onto the windshield wiper motor
crank pin, and install the RH windshield wiper
mounting arm and pivot shaft onto the wiper motor crank pin.
4. Install the cowl top vent panels.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page
12326
Wiper Motor Timer: Description and Operation
Description and Operation
For further information regarding this component and the system that it is a part of, please refer to
Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page
12327
Wiper Motor Timer: Testing and Inspection
Testing and Inspection
For further information regarding the diagnosis of this component and the system that it is a part of,
please refer to Multifunction Electronic Control Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor Timer > Component Information > Locations > Page
12328
Wiper Motor Timer: Service and Repair
SERVICE AND REPAIR
For further information regarding this component please refer to Multifunction Electronic Control
Modules.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay
Wiper Relay: Locations Rear Wiper Up Relay
Part (1 Of 2)
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12333
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12334
Wiper Relay: Locations Rear Wiper Down Relay
Part (1 Of 2)
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12335
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12336
Wiper Relay: Locations Wiper High Relay
Part (1 Of 2)
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12337
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12338
Wiper Relay: Locations Wiper Low Relay
Part (1 Of 2)
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12339
Part (2 Of 2)
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12340
Wiper Relay: Locations Wiper Park Relay
Part (1 Of 2)
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Rear Wiper
Up Relay > Page 12341
Part (2 Of 2)
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 12342
Wiper Relay: Testing and Inspection
Testing an ISO relay can be accomplished through the use of three No.10 (or larger gauge) jumper
wires and 73 Digital Multimeter. Remove the relay to be tested from the power distribution box,
fuse junction panel or individual connector.
Terminals
Component Testing Procedure
Schematic
Micro ISO Relay
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations > Page 12343
Use the multimeter to check for the continuity between terminal 2 and all other terminals. If the
resistance is 5 ohms or less between terminal 2 and any other terminal, replace the relay. If
resistance is greater than 5 ohms, continue with the test. Use two jumper wires to connect relay
terminals 1 and 3 directly to the positive battery terminal. Use the multimeter set in the volts
position to check for voltage at terminal 4. If battery voltage is not indicated, replace the relay. If
battery voltage is indicated, connect a third jumper wire to terminal 2 and ground the jumper wire to
a known good ground. Check for voltage at terminal 5. If battery voltage is not indicated, replace
the relay.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations
Wiper Switch: Locations
Rear Wiper And Washer System
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page
12347
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams >
Multifunction Switch
Wiper Switch: Diagrams Multifunction Switch
For further information regarding this component please refer to:
Lighting and Horns/Diagrams.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams >
Multifunction Switch > Page 12350
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page
12351
Wiper Switch: Testing and Inspection
Multifunction Switch Tests
Component Testing Procedure
Component Testing Procedure
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12352
Component Testing Procedure
Terminals
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page
12353
Schematic
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Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page
12354
Schematic
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair >
Rear Wiper Switch
Wiper Switch: Service and Repair Rear Wiper Switch
REMOVAL
1. Remove the instrument panel finish panel.
1 Remove the two screws.
2 Remove the center instrument panel finish panel. ^
Disconnect the electrical connectors.
2. Remove the rear wiper/washer switch.
1 Remove the screws.
2 Remove the mounting bezel.
3 Release the two tabs and remove the rear wiper/washer switch.
INSTALLATION
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair >
Rear Wiper Switch > Page 12357
1. To install, reverse the removal procedure.
Ford Explorer 4wd Workshop Manual (V6-245 4.0L SOHC VIN K SFI (2001))
Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Service and Repair >
Rear Wiper Switch > Page 12358
Wiper Switch: Service and Repair Multifunction Switch
Removal
1. Disconnect the battery ground cable.
2. Remove the ignition switch lock cylinder.
1 Insert the ignition key into the ignition switch lock cylinder and turn to RUN position.
2 Push the ignition switch lock cylinder release tab with a punch while pulling out the ignition switch
lock cylinder.
3. If equipped, twist the tilt wheel handle and shank counterclockwise and remove.
4. Remove the upper and lower steering column shrouds.
1 Remove the screws.